Note: Descriptions are shown in the official language in which they were submitted.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
1
PROCESS FOR MAKING AN ABSORBENT ARTICLE COMPRISING A
TOPSHEET/ACQUISITION LAYER LAMINATE
FIELD OF THE INVENTION
A process of making an absorbent article comprising a topsheet/acquisition
layer laminate
is provided. Specifically, a process of making an absorbent article comprising
a
topsheet/acquisition layer laminate, a dry-laid fibrous structure and an
optional carrier layer is
provided.
BACKGROUND OF THE INVENTION
An absorbent article typically comprises a topsheet, a backsheet, and an
absorbent core
disposed between the topsheet and the backsheet. The absorbent article
includes an acquisition
layer and optionally a distribution layer. The acquisition layer is able to
receive the liquid bodily
exudates from the topsheet in order to temporary store them. Then, the
distribution layer can
receive the liquid bodily exudates from the acquisition layer and distribute
and transfer them to
the absorbent core in order to make efficient the use of the absorbent core.
Such absorbent
articles exhibit satisfactory fluid handling properties.
Three-dimensional topsheets have been developed; see for example U.S. Patent
application US 2014/0121625 Al.
There still remains a need to further improve three-dimensional topsheets.
There is a need to develop a method to prepare a skin facing layer having a
three-
dimensional structure for an absorbent article providing improved dryness
perception and
improved fluid handling properties e.g. less rewet on the skin facing layer,
while the physical and
perceptional comfort of the wearer as well as the leakage prevention are still
met.
There is also a need to produce a skin facing layer having a three-dimensional
structure in
order to reduce the contact of the liquid bodily exudates with the skin of the
wearer. It is
desirable as well that the skin facing layer provides a softness/cushiness
feeling for the caregiver
and the wearer.
SUMMARY OF THE INVENTION
A process of making an absorbent article is provided and comprises the steps
of:
(a) providing a liquid permeable topsheet web extending substantially
continuously in a
machine direction, the topsheet web having a first and second surface, a
liquid
impermeable backsheet web extending substantially continuously in the machine
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
2
direction and an acquisition layer having a first and second surface, the
topsheet web and
the acquisition layer comprising fibers;
(b) aligning the topsheet web and the acquisition layer in a face to face
relationship such
that the second surface of the topsheet web is in contact with the first
surface of the
acquisition layer;
(c) simultaneously mechanically deforming and combining the topsheet web
together with
the acquisition layer to provide a topsheet/acquisition layer laminate web
having three-
dimensional protrusions,
wherein the three-dimensional protrusions are formed from the fibers of the
topsheet web
and the acquisition layer, wherein a majority of the three-dimensional
protrusions each
comprises a base forming an opening, an opposed distal portion, and one or
more side
walls between the bases and the distal portions of the majority of the three-
dimensional
protrusions, wherein the base, distal portion and the one or more side walls
are formed by
fibers such that the majority of the three-dimensional protrusions has only an
opening at
the base;
wherein a width of the acquisition layer is less than a width of the topsheet
web in a cross
direction;
the topsheet/acquisition layer laminate web having a first surface comprising
the second
surface of the acquisition layer; and
(e) joining a portion of the backsheet web to a portion of the topsheet web of
the
topsheet/acquisition layer laminate web such that the first surface of the
topsheet/acquisition layer laminate web is facing towards the backsheet web.
The process may comprise the step of cutting into individual absorbent
articles
comprising a backsheet, a topsheet and an acquisition layer, characterized in
that the topsheet and
acquisition layer are joined to form a topsheet/acquisition layer laminate.
The process may comprise the steps of:
(a) providing a dry-laid fibrous structure or a wet-laid fibrous structure ;
(b) depositing the dry-laid fibrous structure or the wet-laid fibrous
structure on the first
surface of the topsheet/acquisition layer laminate web or on the backsheet
web; and
(c) joining a portion of the backsheet web to a portion of the topsheet web of
the
topsheet/acquisition layer laminate web wherein the dry-laid fibrous structure
or the
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
3
wet-laid fibrous structure is between the topsheet/acquisition layer laminate
web and
the backsheet web.
A process of making an absorbent article is provided and comprises the steps
of:
(a) providing a liquid permeable topsheet web extending substantially
continuously in a
machine direction, the topsheet web having a first and second surface, a
liquid
impermeable backsheet web extending substantially continuously in the machine
direction, an acquisition layer having a first and second surface, a dry-laid
fibrous
structure and a carrier layer web having a first and second surface, the
topsheet web and
the acquisition layer comprising fibers;
(b) aligning the topsheet web and the acquisition layer in a face to face
relationship such
that the second surface of the topsheet web is in contact with the first
surface of the
acquisition layer;
(c) simultaneously mechanically deforming and combining the topsheet web
together with
the acquisition layer to provide a topsheet/acquisition layer laminate web
having three-
dimensional protrusions,
wherein the three-dimensional protrusions are formed from the fibers of the
topsheet web
and the acquisition layer, wherein a majority of the three-dimensional
protrusions each
comprises a base forming an opening, an opposed distal portion, and one or
more side
walls between the base and the distal portion of the majority of the three-
dimensional
protrusions, wherein the base, distal portion and the one or more side walls
are formed by
fibers such that the majority of the three-dimensional protrusion has only an
opening at
the base;
wherein a width of the acquisition layer is less than a width of the topsheet
web in a cross
direction;
the topsheet/acquisition layer laminate web having a first surface comprising
the second
surface of the acquisition layer;
(d) depositing the dry-laid fibrous structure on the first surface of the
carrier layer web;
and
(e) joining a portion of the backsheet web to a portion of the topsheet web of
the
topsheet/acquisition layer laminate web such that the second surface of the
carrier layer
web is facing the topsheet/acquisition layer laminate web or the backsheet
web.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
4
The process may comprise the step of cutting into individual absorbent
articles
comprising a backsheet, a carrier layer, a topsheet and an acquisition layer
characterized in that
the topsheet and acquisition layer are joined to form a topsheet/acquisition
layer laminate.
A majority of the three-dimensional protrusions may be more than 50% or more
than 60%
or more than 70% or more than 80% or more than 90% or more than 95% or more
than 98% of
the three-dimensional protrusions in the topsheet/acquisition layer laminate
web or in the
topsheet/acquisition layer laminate.
The topsheet web and the acquisition layer in the topsheet/acquisition layer
laminate web
may be in an intimate contact with each other.
The maximum interior width of the void area at the distal portion may be
greater than the
protrusion base width of the base of the majority of the three-dimensional
protrusions.
Measurements of the protrusion base width of the base or the maximum interior
width of the void
area at the distal portion can be made on a photomicrograph at 20X
magnification.
The fibers of the topsheet and acquisition layer in the area of the three-
dimensional
protrusions of the topsheet/acquisition layer laminate may substantially or
completely surround
the one or more side walls of the majority of the three-dimensional
protrusions.
The majority of the three-dimensional protrusions may be configured to
collapse in a
controlled manner such that each base forming an opening remains open, and the
protrusion base
width of each base forming an opening is greater than 0.5 mm after compression
according to
Accelerated Compression Method.
The width of the acquisition layer of the topsheet/acquisition layer laminate
may not
wider more than 40% of the width of the distribution layer and/or more than
20% of the width of
the absorbent core.
The absorbent article may comprise gasketing cuffs.
The majority of the three-dimensional protrusions of the topsheet/acquisition
layer
laminate may at least or only be present in the area where the topsheet
overlaps the acquisition
layer in the topsheet/acquisition layer laminate.
The majority of the three-dimensional protrusions of the topsheet/acquisition
layer
laminate may be present in the area which extends parallel to the transversal
axis of the absorbent
article. The majority of the three-dimensional protrusions of the
topsheet/acquisition layer
laminate may be present in the area which extends parallel to the longitudinal
axis of the
absorbent article, but which does not extend beyond the area where gasketing
cuffs is attached to
the absorbent article. In that case, the three-dimensional protrusions which
are formed in the
topsheet of the topsheet/acquisition layer laminate, are formed from the
fibers of the topsheet.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
The majority of the three-dimensional protrusions of the topsheet/acquisition
layer
laminate may protrude towards the backsheet. The majority of the three-
dimensional protrusions
of the topsheet/acquisition layer laminate may comprise a distal end in
contact with the second
surface of the carrier layer. The second surface of the carrier layer may be
attached to the distal
5 ends
of the majority of the three-dimensional protrusions of the
topsheet/acquisition layer
laminate.
The topsheet/acquisition layer laminate web may comprise a plurality of three-
dimensional protrusions protruding towards the backsheet web or towards the
body of the wearer
when the absorbent article is in use.
The process may comprise the step of providing the topsheet web with a first
region of the
topsheet and the acquisition layer with a first region of the acquisition
layer; wherein the
concentration of fibers in the first region of the acquisition layer and in
the distal ends of the
majority of the three dimensional protrusions is greater than the
concentration of fibers in the
side walls of the majority of the three dimensional protrusions in the
acquisition layer; and
wherein the concentration of fibers in the first region of the topsheet and in
the distal ends of the
majority of the three dimensional protrusions is greater than the
concentration of fibers in the
side walls of the majority of the three dimensional protrusions in the
topsheet.
The process may comprise the step of providing the topsheet web with a first
region of the
topsheet and the acquisition layer with a first region of the acquisition
layer; wherein the
concentration of fibers in the first region of the acquisition layer is
greater than the concentration
of fibers in the distal ends of the majority of the three dimensional
protrusions in the acquisition
layer; and wherein the concentration of fibers in the first region of the
topsheet and the distal
ends of the majority of the three dimensional protrusions is greater than the
concentration of
fibers in the side walls of the majority of the three dimensional protrusions
in the topsheet.
The process may comprise the step of providing the topsheet web with a first
region of the
topsheet and the acquisition layer with a first region of the acquisition
layer; wherein the
concentration of fibers in the first region of the acquisition layer is
greater than the concentration
of fibers in the side walls of the majority of the three dimensional
protrusions in the acquisition
layer; and wherein the concentration of fibers in the side walls of the
majority of the three
dimensional protrusions in the acquisition layer is greater than the
concentration of fibers
forming the distal ends of the majority of the three dimensional protrusions
in the acquisition
layer.
The process according may comprise the step of applying an indicia to the
topsheet web,
the acquisition layer, and/or the carrier layer web.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
6
The process may comprise the step of printing an indicia on the topsheet web,
the
acquisition layer, and/or the carrier layer web.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and
distinctly claiming
the present invention, it is believed that the same will be better understood
from the following
description read in conjunction with the accompanying drawings in which:
Fig. 1 is an absorbent article in the form of a diaper comprising an exemplary
topsheet/acquisition layer laminate wherein the length of the acquisition
layer is less that the
length of the topsheet according to the present invention with some layers
partially removed;
Fig. 2 is a transversal cross-section of the diaper of Fig. 1;
Fig. 3 is a transversal cross-section of the diaper of Fig. 1;
Fig. 4 is an absorbent article in the form of a diaper comprising an exemplary
topsheet/acquisition layer laminate wherein the three-dimensional protrusions
of the
topsheet/acquisition layer laminate are only formed where the topsheet
overlaps the acquisition
layer in the topsheet/acquisition layer laminate, according to the present
invention with some
layers partially removed;
Fig. 5 is an absorbent article in the form of a diaper comprising an exemplary
topsheet/acquisition layer laminate with another type of absorbent core
according to the present
invention with some layers partially removed;
Fig. 6 is a transversal cross-section of a diaper of Fig. 5;
Fig. 7 is a transversal cross-section of the absorbent article of Fig. 5 taken
at the same point as
Fig. 6 where channels have formed as a result the absorbent article being
loaded with liquid
bodily exudates;
Fig. 8 is a side schematic view of an example of a process according to the
present invention;
Fig. 9 is a side schematic view of another example of a process according to
the present
invention;
Fig. 10 is a side schematic view of another example of a process according to
the present
invention;
Fig. 11 is an absorbent article in the form of a diaper comprising an
exemplary
topsheet/acquisition layer laminate with a carrier layer according to the
present invention with
some layers partially removed;
Fig. 12A is a transversal cross-section of the diaper of Fig. 11;
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
7
Fig. 12B is another transversal cross-section of the diaper of Fig. 11;
Fig. 13 is an absorbent article in the form of a diaper comprising an
exemplary
topsheet/acquisition layer laminate with a carrier layer according to the
present invention with
some layers partially removed;
Fig. 14 is a transversal cross-section of the diaper of Fig. 13;
Fig. 15 is an absorbent article in the form of a diaper comprising an
exemplary
topsheet/acquisition layer laminate with an acquisition layer positioned in a
front region of the
absorbent article according to the present invention with some layers
partially removed;
Fig. 16 is an absorbent article in the form of a diaper comprising an
exemplary
topsheet/acquisition layer laminate with an acquisition layer positioned in a
rear region of the
absorbent article according to the present invention with some layers
partially removed;
Fig. 17A is a perspective view of an apparatus comprising a first and second
forming member for
forming the topsheet/acquisition layer laminate web of the present invention;
Fig. 17B is a perspective view of a portion of the first forming member of the
apparatus shown in
Fig. 17A;
Fig. 17C is a perspective view of the apparatus shown in Fig. 17A, showing the
first forming
member intermeshing the second forming member;
Fig. 18A is a perspective view of a three-dimensional protrusion of the
topsheet/acquisition layer
laminate obtained with the apparatus shown in Fig. 17A;
Fig. 18B is a schematic view of a three-dimensional protrusion of the
topsheet/acquisition layer
laminate obtained with the apparatus shown in Fig. 17A;
Fig. 18C is a schematic view of a three-dimensional protrusion of the
topsheet/acquisition layer
laminate obtained with the apparatus shown in Fig. 17A;
Fig. 18D is a schematic view of a three-dimensional protrusion of the
topsheet/acquisition layer
laminate obtained with the apparatus shown in Fig. 17A;
Fig. 18E is a schematic view of a three-dimensional protrusion of the
topsheet/acquisition layer
laminate obtained with the apparatus shown in Fig. 17A;
Fig. 18F is a schematic view of a three-dimensional protrusion of the
topsheet/acquisition layer
laminate obtained with the apparatus shown in Fig. 17A;
Fig. 19A is a schematic view of a three-dimensional protrusion of the
topsheet/acquisition layer
laminate obtained with the apparatus shown in Fig. 17A;
Fig. 19B is a schematic view of a three-dimensional protrusion of the
topsheet/acquisition layer
laminate obtained with the apparatus shown in Fig. 17A;
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
8
Fig. 19C is a schematic view of a three-dimensional protrusion of the
topsheet/acquisition layer
laminate obtained with the apparatus shown in Fig. 17A;
Fig. 19D is a schematic view of a three-dimensional protrusion of the
topsheet/acquisition layer
laminate obtained with the apparatus shown in Fig. 17A;
Fig. 19E is a schematic view of a three-dimensional protrusion of the
topsheet/acquisition layer
laminate obtained with the apparatus shown in Fig. 17A.
DETAILED DESCRIPTION OF THE INVENTION
Definition of terms
The term "absorbent article" as used herein refers to disposable products such
as diapers,
pants or feminine hygiene sanitary napkins and the like which are placed
against or in proximity
to the body of the wearer to absorb and contain the various liquid bodily
exudates discharged
from the body. Typically these absorbent articles comprise a topsheet,
backsheet, an absorbent
core and optionally an acquisition layer and/or distribution layer and other
components, with the
absorbent core normally placed between the backsheet and the acquisition
system or topsheet.
The absorbent article of the present invention may be a diaper or pant.
The term "diaper" as used herein refers to an absorbent article that is
intended to be worn
by a wearer about the lower torso to absorb and contain liquid bodily exudates
discharged from
the body. Diapers may be worn by infants (e.g. babies or toddlers) or adults.
They may be
provided with fastening elements.
The term "pant" as used herein refers to an absorbent article having fixed
edges, a waist
opening and leg openings designed for infant or adult wearers. A pant is
placed in position on the
wearer by inserting the wearer's legs into the leg openings and sliding the
pant-type absorbent
article into position about the wearer's lower torso. A pant may be preformed
by any suitable
technique including, but not limited to, joining together portions of the
absorbent article using
refastenable and/or non-refastenable bonds (e.g., seam, weld, adhesive,
cohesive bond, fastener,
etc.). A pant may be preformed anywhere along the circumference of the article
(e.g., side
fastened, front waist fastened).
The term "extensible" as used herein refers to a material, which, upon
application of a
force, is capable of undergoing an apparent elongation of equal to or greater
than at least 100% of
its original length in the machine and/or cross-machine directions at or
before reaching the
breaking force if subjected to the following test:
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
9
The MD and CD tensile properties are measured using a method using WSP 110.4
(05)
Option B, with a 50 mm sample width, 60 mm gauge length, and 60 mm/min rate of
extension.
It may be desirable that a material is capable of undergoing an apparent
elongation of
equal to or greater than at least 100% or 110% or 120% or 130% up to 200% in
the machine
and/or cross-machine directions at or before reaching the breaking force
according to the Test
Method as set out above.
If a material is capable of undergoing an apparent elongation of less than 100
% of its
original length if subjected to the above described test, it is "non-
extensible" as used herein.
The term "topsheet/acquisition layer laminate web" as used herein refers to an
intimate
combination of a topsheet web with an acquisition layer, both disposed in a
face to face
relationship. The topsheet web has a first and second surface. The first
surface of the topsheet
web is facing towards the body of the wearer when the absorbent article is in
use. The acquisition
layer is facing the backsheet web or the optional distribution layer. The
topsheet web and the
acquisition layer have undergone a simultaneous and joint mechanical
deformation while the
topsheet web and the acquisition layer are combined with each other. The
topsheet/acquisition
layer laminate web comprises deformations forming three-dimensional
protrusions.
In the topsheet/acquisition layer laminate web, the topsheet web and
acquisition layer
may be in an intimate contact with each other.
The topsheet/acquisition layer laminate web may be formed by nesting together
the
topsheet web and acquisition layer, wherein the three-dimensional protrusions
of the topsheet
web coincide with and fit together with the three-dimensional protrusions of
the acquisition layer,
as shown in Figs. 18B and 19A. The topsheet web and acquisition layer may be
both extensible
such that the topsheet web and acquisition layer are able to stretch.
Alternatively or in addition to what has been set out above, the
topsheet/acquisition layer
laminate web may be formed by interrupting one of the topsheet web or
acquisition layer such
that the three-dimensional protrusions of the respective other non-interrupted
topsheet web or
acquisition layer interpenetrate the interrupted topsheet web or acquisition
layer, as shown in
Figs. 18C and 19B.
In still another alternative or in addition to what has been set out above,
the
topsheet/acquisition layer laminate web may be formed by interrupting one of
the topsheet web
or acquisition layer in the area of the three-dimensional protrusions of the
topsheet/acquisition
layer laminate web such that the three-dimensional protrusions of the
respective other non-
interrupted topsheet web or acquisition layer at least partially fit together
with the three-
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
dimensional protrusions of the interrupted topsheet web or acquisition layer,
as shown in Figs.
18D, 18E, 19C and 19D.
In another alternative or in addition to what has been set out above, the
topsheet/acquisition layer laminate web may be formed by interrupting the
topsheet web and
5 acquisition layer in the area of the three-dimensional protrusions of the
topsheet/acquisition layer
laminate web and the three-dimensional protrusions of the topsheet web
coincide with and fit
together with the three-dimensional protrusions of the acquisition layer. If
the topsheet web and
acquisition layer comprise interruptions in the area of the three-dimensional
protrusions, the
interruptions in the topsheet web in the area of the three-dimensional
protrusions of the
10 topsheet/acquisition layer laminate web will not coincide with the
interruptions in the acquisition
layer in the area of the three-dimensional protrusions of the
topsheet/acquisition layer laminate
web, as shown in Figs. 18F and 19E.
The terms "interruptions", as used herein, refer to holes formed in the
topsheet web
and/or acquisition layer during the formation of the topsheet/acquisition
layer laminate web, and
does not include the pores and interstices between fibers typically present in
nonwovens.
The term "mechanically deforming and combining" as used herein means that the
topsheet web and acquisition layer are put in a face to face relationship and
are simultaneously
mechanically deformed between a first and second roll and intimately combined
at the same
time. The mechanical deformation of the topsheet web and acquisition layer
depends on the
process, the required apparatus but also on the properties of the topsheet web
and acquisition
layer, i.e. apparent elongation of the fibers, fiber mobility, ability to
deform and stretch in the
area where the three-dimensional protrusions of the topsheet/acquisition layer
laminate web are
formed, ability to undergo plastic deformation which sets after existing the
first and second roll,
or springing partially back due to elastic recovery.
The mechanical deformation may comprise engaging the topsheet web and the
acquisition
layer together between a first and second forming member such that a plurality
of deformations
comprising three-dimensional protrusions are obtained. The three-dimensional
protrusions are
formed form the fibers of the topsheet web and the acquisition layer. A
majority of the three-
dimensional protrusions is defined by a base forming an opening, an opposed
distal portion and
the one or more side wall between the base and the distal portion of the
majority of the three-
dimensional protrusions. The base, distal portion and one or more side wall
are formed by fibers
such that the majority of the three-dimensional protrusions has only an
opening at the base, as
shown in Fig. 18A.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
11
The term "topsheet/acquisition layer laminate" as used herein refers to an
intimate
combination of a topsheet with an acquisition layer, both disposed in a face
to face relationship.
The topsheet has a first and second surface. The first surface of the topsheet
is facing towards the
body of the wearer when the absorbent article is in use. The acquisition layer
is facing the
backsheet or the optional distribution layer. The topsheet and the acquisition
layer have
undergone a simultaneous and joint mechanical deformation while the topsheet
and the
acquisition layer are combined with each other. The topsheet/acquisition layer
laminate
comprises deformations forming three-dimensional protrusions.
For the majority of the three-dimensional protrusions of the resulting
topsheet/acquisition
layer laminate:
- The topsheet may be nested into the acquisition layer or vice versa such
that the three-
dimensional protrusions of the topsheet and of the acquisition layer coincide
with and
fit together, as shown in Figs. 18B and 19A.
- Alternatively or in addition to what has been set out above, one of the
topsheet or
acquisition layer may be interrupted in the area of the three-dimensional
protrusions
of the topsheet/acquisition layer laminate such that the three-dimensional
protrusions
made of the respective other non-interrupted topsheet or acquisition layer
interpenetrate the interruptions of the topsheet or of the acquisition layer,
as shown in
Figs. 18C and 19B.
- Alternatively or in addition to what has been set out above, one of the
topsheet or
acquisition layer may be interrupted in the area of the three-dimensional
protrusions
of the topsheet/acquisition layer laminate such that the three-dimensional
protrusions
made of the respective other non-interrupted topsheet or acquisition layer at
least
partially fit together with the three-dimensional protrusions of the
interrupted topsheet
or of the interrupted acquisition layer, as shown in Figs. 18D, 18E, 19C and
19D.
- Alternatively or in addition to what has been set out above, the topsheet
and
acquisition layer may be interrupted in the area of the three-dimensional
protrusions
of the topsheet/acquisition layer laminate and the three-dimensional
protrusions of the
topsheet coincide with and fit together with the three-dimensional protrusions
of the
acquisition layer. The interruptions in the topsheet in the area of the three-
dimensional
protrusions of the topsheet/acquisition layer laminate may not coincide with
the
interruptions in the acquisition layer in the area of the three-dimensional
protrusions
of the topsheet/acquisition layer laminate, as shown in Figs. 18F and 19E.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
12
The term "a majority of the three-dimensional protrusions" as used herein
means that
more than 50% or more than 60% or more than 70% or more than 80% or more than
90% or
more than 95% or more than 98% of the three-dimensional protrusions in the
topsheet/acquisition
layer laminate web or in the topsheet/acquisition layer laminate of the
absorbent article, each
comprises a base forming an opening, an opposed distal portion and the one or
more side wall
between the base and the distal portion of the three-dimensional protrusion.
The base, distal
portion and one or more side wall are formed by fibers such that the three-
dimensional protrusion
has only an opening at the base (as exemplary shown in a Fig. 18A).
The term "machine direction" or "MD" as used herein means the path that
material, such
as a web, follows through a manufacturing process.
The term "cross-machine direction" or "CD" as used herein means the path that
is
perpendicular to the machine direction in the plane of the web.
The term "cellulosic fiber" as used herein refers to natural fibers which
typically are
wood pulp fibers. Applicable wood pulps include chemical pulps, such as Kraft,
sulfite, and
sulfate pulps, as well as mechanical pulps including, for example, groundwood,
thermomechanical pulp and chemically modified thermomechanical pulp. Pulps
derived from
both deciduous trees (hereinafter, also referred to as "hardwood") and
coniferous trees
(hereinafter, also referred to as "softwood") may be utilized. The hardwood
and softwood fibers
can be blended, or alternatively, can be deposited in layers to provide a
stratified web.
The term "dry-laid fiber" as used herein means fibers which have been provided
in a fluid
medium which is gaseous (air).
The term "wet-laid fiber" as used herein comprises cellulosic fibers which
have been
suspended in an aqueous medium, such as water, before being converted into a
web and dried
according to a wet-laid papermaking process.
The term "web" as used herein means a material capable of being wound into a
roll.
Webs may be nonwovens.
The term "nonwoven web" as used herein refers to a manufactured material, web,
sheet or
batt of directionally or randomly oriented fibers, bonded by friction, and/or
cohesion and/or
adhesion, excluding paper and products which are woven, knitted, tufted,
stitch-bonded,
incorporating binding yarns or filaments, or felted by wet milling, whether or
not additionally
needled. The fibers may be of natural or man-made origin. The fibers may be
staple or
continuous filaments or be formed in situ. The porous, fibrous structure of a
nonwoven may be
configured to be liquid permeable or impermeable, as desired.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
13
The term "absorbent core" as used herein refers to a component, which is
placed or is
intended to be placed within an absorbent article and which comprises an
absorbent material
enclosed in a core wrap. The term "absorbent core" does not include an
acquisition or
distribution layer or any other component of an absorbent article which is not
either an integral
part of the core wrap or placed within the core wrap. The absorbent core is
typically the
component of an absorbent article which comprises all, or at least the
majority of, superabsorbent
polymer and has the highest absorbent capacity of all the components of the
absorbent article.
The term "substantially free of absorbent material" or "substantially
absorbent material
free" as used herein means that the basis weight of the absorbent material in
the substantially
absorbent material free areas is at least less than 10%, in particular less
than 5%, or less than 2%,
of the basis weight of the absorbent material in the rest of the absorbent
core.
The term "superabsorbent polymers" (herein abbreviated as "SAP") as used
herein refer
to absorbent materials which are cross-linked polymeric materials that can
absorb at least 10
times their weight of an aqueous 0.9% saline solution as measured using the
Centrifuge
Retention Capacity (CRC) test (EDANA method WSP 241.2-05E). The SAP of the
invention
may in particular have a CRC value of more than 20 g/g, or more than 25 g/g,
or from 20 to 50
g/g, or from 20 to 40 g/g, or 25 to 35 g/g. The SAP useful in the invention
includes a variety of
water-insoluble, but water-swellable polymers capable of absorbing large
quantities of liquid
bodily exudates.
The term "joined to" as used herein encompasses configurations in which an
element is
directly secured to another element by affixing the element directly to the
other element; and
configurations in which the element is indirectly secured to the other element
by affixing the
element to intermediate member(s) which in turn are affixed to the other
element. The term
"joined to" encompasses configurations in which an element is secured to
another element at
selected locations, as well as configurations in which an element is
completely secured to another
element across the entire surface of one of the elements. The term "joined to"
includes any
known manner in which elements can be secured including, but not limited to
mechanical
entanglement.
The term "joined adjacent to the transversal edges" as used herein means that
when a first
and/or second transversal edge of a first layer is/are joined adjacent to a
first and/or second
transversal edges of a second layer, the first and/or second transversal edge
of the first layer are
disposed within an area spaced inboard from the first and/or second
transversal edge of the
second layer. The area has a width which is from 1 to 30% of the width of the
second layer.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
14
"Comprise," "comprising," and "comprises" are open ended terms, each specifies
the
presence of the feature that follows, e.g. a component, but does not preclude
the presence of other
features, e.g. elements, steps, components known in the art or disclosed
herein. These terms
based on the verb "comprise" should be read as encompassing the narrower terms
"consisting
essential of' which excludes any element, step or ingredient not mentioned
which materially
affect the way the feature performs its function, and the term "consisting of'
which excludes any
element, step, or ingredient not specified. Any preferred or exemplary
embodiments described
below are not limiting the scope of the claims, unless specifically indicated
to do so. The words
"typically", "normally", "advantageously" and the likes also qualify features
which are not
intended to limit the scope of the claims unless specifically indicated to do
so.
General description of the absorbent article 20
An exemplary absorbent article 20 in which the absorbent core 28 of the
invention can be
used is a taped diaper 20 as represented in Fig. 1; Fig. 4 and Fig. 5 with a
different absorbent core
construction. Fig. 1; Fig. 4 and Fig. 5 are top plan views of the exemplary
diaper 20, in a flat-out
state, with portions of the structure being cut-away to more clearly show the
construction of the
diaper 20. This diaper 20 is shown for illustration purpose only as the
invention may be used for
making a wide variety of diapers or other absorbent articles.
The absorbent article 20 comprises a topsheet/acquisition layer laminate 245
formed from
a liquid permeable topsheet 24 and an acquisition layer 52. In other words,
the absorbent article
20 comprises a liquid permeable topsheet 24 and an acquisition layer 52
characterized in that the
topsheet 24 and acquisition layer 52 are joined to form a topsheet/acquisition
layer laminate 245.
The absorbent article 20 comprises a liquid impermeable backsheet 25 and an
absorbent core 28
between the topsheet 24 and the backsheet 25. The absorbent article 20
comprises a front edge
10, a back edge 12, and two longitudinal side edges 13. The front edge 10 is
the edge of the
absorbent article 20 which is intended to be placed towards the front of the
user when worn, and
the back edge 12 is the opposite edge. The absorbent article 20 may be
notionally divided by a
longitudinal axis 80 extending from the front edge 10 to the back edge 12 of
the absorbent article
20 and dividing the absorbent article 20 in two substantially symmetrical
halves relative to this
axis, when viewing the absorbent article 20 from the wearer facing side in a
flat out
configuration, as exemplarily shown in Fig. 1, Fig. 4 and Fig. 5.
The absorbent article 20 may comprise a distribution layer 54 which may
comprise a dry-
laid fibrous structure or wet-laid fibrous structure . The
topsheet/acquisition layer laminate 245 is
facing towards the body of the wearer when the absorbent article 20 is in use.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
The wet-laid fibrous structure comprising wet-laid fibers may have a Wet burst
Strength
from 50 to 500 g according to the Wet Burst Strength Test Method and
combinations thereof.
The distribution layer 54 may comprise a dry-laid fibrous structure. The dry-
laid fibrous
structure may comprise dry-laid fibers. The dry-laid fibrous structure may
comprise a mixture
5 including superabsorbent polymers and dry-laid fibers. The dry-laid
fibers may comprise intra-
fiber cross-linked cellulosic fibers.
The distribution layer 54 may comprise a wet-laid fibrous structure. The wet-
laid fibrous
structure may comprise wet-laid fibers.
The distribution layer 54 may have an average basis weight of from 30 to 400
gsm, in
10 particular from 100 to 300 gsm or from 50 to 250 gsm.
As explained more in a process detailed below, a topsheet web 240 and an
acquisition
layer 52 are simultaneously mechanically deformed and combined together to
form a
topsheet/acquisition layer laminate web 2450. The topsheet/acquisition layer
laminate web 2450
forms the topsheet/acquisition layer laminate 245 in the absorbent article 20.
The
15 topsheet/acquisition layer laminate 245 comprises mechanical
deformations forming three-
dimensional protrusions 250. The mechanical deformations provide a three-
dimensional structure
to the topsheet/acquisition layer laminate 245.
The absorbent article 20 may comprise elasticized gasketing cuffs 32 present
between the
topsheet 24 and the backsheet 25 and upstanding bather leg cuffs 34. Figs. 1,
4 and 5 also show
other typical diaper components such as a fastening system comprising
fastening tabs 42 attached
towards the back edge 12 of the absorbent article 20 and cooperating with a
landing zone 44
towards the front edge 10 of the absorbent article 20. The absorbent article
20 may also comprise
other typical components, which are not represented in the Figures, such as a
back elastic waist
feature, a front elastic waist feature, transverse barrier cuff(s), a lotion
application, etc.
As shown in Fig. 7, the bather leg cuffs 34 may be delimited by a proximal
edge 64
joined to the rest of the absorbent article 20, typically the topsheet 24
and/or the backsheet 25,
and a free terminal edge intended to contact and form a seal with the wearer's
skin. The barrier
leg cuffs 34 may be joined at the proximal edge 64 by a bond 65 which may be
made for example
by adhesive bonding, fusion bonding or combination of known bonding means.
Each barrier leg
cuff 34 may comprise one, two or more elastic strings 35 to provide a better
seal. The gasketing
cuffs 32 may be placed laterally outwardly relative to the barrier leg cuffs
34. The gasketing
cuffs 32 can provide a better seal around the thighs of the wearer. Usually
each gasketing leg cuff
32 will comprise one or more elastic string or elastic element 33 for example
between the
topsheet 24 and the backsheet 25 in the area of leg openings.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
16
The absorbent article 20 can also be notionally divided by a transversal axis
90 in a front
region and a back region of equal length measured on the longitudinal axis,
when the absorbent
article 20 is in a flat state. The absorbent article's transversal axis 90 is
perpendicular to the
longitudinal axis 80 and placed at half the length of the absorbent article
20. The length of the
absorbent article 20 can be measured along the longitudinal axis 80 from the
front edge 10 to the
back edge 12 of the absorbent article 20. The topsheet 24, acquisition layer
52, distribution layer
54 and absorbent core 28 each have a width which can be measured from their
respective
transversal edges and in parallel to the transversal axis 90.
The absorbent article 20 is notionally divided in a front region 36, a back
region 38 and a
crotch region 37 located between the front and the back region of the
absorbent article 20. Each
of the front, back and crotch region is 1/3 of the length of the absorbent
article 20. The absorbent
article may also comprise front ears 46 and back ears 40 as it is known in the
art.
The absorbent core 28 of the present invention may comprise as absorbent
material 60 a
blend of cellulosic fibers (so called "airfelt") and superabsorbent polymers
in particulate form
encapsulated in one or more substrates, see for example US 5,151,092 (Buell).
Alternatively, the
absorbent core 28 may be airfelt free as described in detail below.
Generally, the absorbent core 28 can be defined by the periphery of the layer
formed by
the absorbent material 60 within the core wrap 160, as seen from the top side
of the absorbent
core 28. The absorbent core 28 can take various shapes, in particular display
a so-called "dog
bone" or "hour-glass" shape, which shows a tapering along its width towards
the middle or
"crotch" region of the core. In this way, the absorbent core 28 may have a
relatively narrow
width in an area of the absorbent core 28 intended to be placed in the crotch
region of the
absorbent article. This may provide for example better wearing comfort. The
absorbent core 28
may thus have a width (as measured in the transversal direction) at its
narrowest point which is
less than about 100 mm, 90 mm, 80 mm, 70 mm, 60 mm or even less than about 50
mm. The
absorbent core 28 can also be generally rectangular, see for example as shown
in Fig. 5, but other
deposition areas can also be used such as a "T" or "Y" or "hour-glass" or "dog-
bone" shape (See
for example Fig. 4).
Some components of the absorbent article 20 will now be discussed in more
details.
"Airfelt-free" absorbent core 28
The absorbent core 28 of the invention may comprise an absorbent material 60
enclosed
within a core wrap 160. The absorbent material 60 may comprise from 80% to
100% of SAP,
such as SAP particles, by total weight of the absorbent material 60. The core
wrap 160 is not
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
17
considered as an absorbent material 60 for the purpose of assessing the
percentage of SAP in the
absorbent core 28.
By "absorbent material" it is meant a material which has at least some
absorbency and/or
liquid retaining properties, such as SAP, cellulosic fibers as well as some
hydrophilically treated
synthetic fibers. Typically, adhesives used in making absorbent cores have no
absorbency
properties and are not considered as absorbent material. The SAP content may
be substantially
higher than 80%, for example at least 85%, at least 90%, at least 95% and even
up to and
including 100% of the weight of the absorbent material 60 contained within the
core wrap 160.
This above SAP content substantially higher than 80% SAP may provide a
relatively thin
absorbent core 28 compared to conventional absorbent cores typically
comprising between 40-
60% SAP and 40-60% of cellulosic fibers. The absorbent material 60 of the
invention may in
particular comprise less than 10% weight percent, or less than 5% weight
percent, or even be
substantially free of natural and/or synthetic fibers. The absorbent material
60 may
advantageously comprise little or no cellulosic fibers, in particular the
absorbent core 28 may
comprise less than 15%, 10%, or 5% (airfelt) cellulosic fibers by weight of
the absorbent core 28,
or even be substantially free of cellulose fibers. Such absorbent core 28 may
be relatively thin
and thinner than conventional airfelt cores. Fig. 1, Fig. 2 and Fig. 3 are
illustrations of an
absorbent article 20 comprising an "airfelt-free" absorbent core 28.
"Airfelt-free" absorbent cores 28 comprising relatively high amount of SAP
with various
absorbent core designs have been proposed in the past, see for example in US
5,599,335
(Goldman), EP1447066A1 (Busam), W095/11652 (Tanzer), U52008/0312622A1
(Hundorf),
and W02012/052172 (Van Malderen).
The absorbent core 28 of the invention may comprise adhesive for example to
help
immobilizing the SAP within the core wrap 160 and/or to ensure integrity of
the core wrap 160 in
particular when the core wrap 160 is made of one or more substrates. The core
wrap 160 will
typically extend over a larger area than strictly needed for containing the
absorbent material 60
within.
Core wrap
The absorbent material 60 is encapsulated in one or more substrates. The core
wrap 160
comprises a top side 16 facing the topsheet 24 and a bottom side 16' facing
the backsheet 25. The
core wrap 160 may be made of a single substrate folded around the absorbent
material 60. The
core wrap 160 may be made of two substrates (one mainly providing the top side
16 and the other
mainly providing the bottom side 16') which are attached to another, as
exemplarily shown in
Fig. 2. Typical configurations are the so-called C-wrap and/or sandwich wrap.
In a C-wrap, as
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
18
exemplarily shown in Fig. 6, the longitudinal and/or transversal edges of one
of the substrate are
folded over the other substrate to form flaps. These flaps are then bonded to
the external surface
of the other substrate, typically by bonding with an adhesive. The so called C-
wrap construction
can provide benefits such as improved resistance to bursting in a wet loaded
state compared to a
sandwich seal.
The core wrap 160 may be formed by any materials suitable for receiving and
containing
the absorbent material 60. The core wrap 160 may in particular be formed by a
nonwoven web,
such as a carded nonwoven, spunbond nonwoven ("S") or meltblown nonwoven
("M"), and
laminates of any of these. For example spunmelt polypropylene nonwovens are
suitable, in
particular those having a laminate web SMS, or SMMS, or SSMMS, structure, and
having a basis
weight range of about 5 gsm to 15 gsm. Suitable materials are for example
disclosed in US
7,744,576, US2011/0268932A1, U52011/0319848A1 or U52011/0250413A1. Nonwoven
materials provided from synthetic fibers may be used, such as polyethylene
(PE), polyethylene
terephthalate (PET) and in particular polypropylene (PP).
"Airfelt-free" absorbent core 28 comprising substantially absorbent material
free areas 26
The absorbent core 28 may comprise an absorbent material deposition area 8
defined by
the periphery of the layer formed by the absorbent material 60 within the core
wrap 160.
The absorbent core 28 may comprise one or more substantially absorbent
material free
area(s) 26 which is/are substantially free of absorbent material 60 and
through which a portion of
the top side 16 of the core wrap 160 is attached by one or more core wrap
bond(s) 27 to a portion
of the bottom side 16' of the core wrap 160, as shown in Figs. 5 and 6. In
particular, there can be
no absorbent material 60 in these areas. Minimal amount such as contaminations
with absorbent
material 60 that may occur during the making process are not considered as
absorbent material
60. The one or more substantially absorbent material free area(s) 26 may be
advantageously
confined by the absorbent material 60, which means that the substantially
absorbent material free
area(s) 26 do(es) not extend to any of the edge of the absorbent material
deposition area 8.
If the substantially absorbent material free area 26 extends to any of the
edges of the
absorbent material deposition area 8, each substantially absorbent material
free area 26 may have
areas of absorbent material 60 on either side of each substantially absorbent
material free area 26.
The absorbent core 28 may comprise at least two substantially absorbent
material free
areas 26 symmetrically disposed on both sides of the longitudinal axis of the
absorbent core 28,
as shown in Fig. 5.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
19
The substantially absorbent material free area(s) 26 may be straight and
completely
oriented longitudinally and parallel to the longitudinal axis but also may be
curved or have one or
more curved portions.
Furthermore, in order to reduce the risk of liquid bodily exudate leakages,
the
substantially absorbent material free area(s) 26 advantageously do not extend
up to any of the
edges of the absorbent material deposition area 8, and are therefore
surrounded by and fully
encompassed within the absorbent material deposition area 8 of the absorbent
core 28. Typically,
the smallest distance between a substantially absorbent material free area 26
and the closest edge
of the absorbent material deposition area 8 is at least 5 mm.
"Airfelt free" absorbent cores 28 comprising substantially absorbent material
free areas
26 have been proposed, see for example in EP Patent Application No.
12196341.7.
One or more channel(s) 26' along the substantially absorbent material free
area(s) 26 in
the absorbent core 28 may start forming when the absorbent material 60 absorbs
a liquid and
starts swelling. As the absorbent core 28 absorbs more liquid, the depressions
within the
absorbent core 28 formed by the channel(s) 26' will become deeper and more
apparent to the eye
and the touch. The formation of the channel(s) 26' may also serve to indicate
that the absorbent
article 20 has been loaded with liquid bodily exudates. The core wrap bond(s)
27 should remain
substantially intact at least during a first phase as the absorbent material
60 absorbs a moderate
quantity of liquid bodily exudates.
As shown in Fig. 7, when the absorbent material swells, the core wrap bonds 27
remain at
least initially attached in the substantially absorbent material free areas
26. The absorbent
material 60 swells in the rest of the absorbent core 28 when it absorbs a
liquid, so that the core
wrap thus forms channels 26' along the substantially absorbent material free
areas 26 comprising
the core wrap bonds 27.
The process of making the absorbent article having a topsheet/acquisition
layer laminate
web
A topsheet/acquisition layer laminate 245 having a three-dimensional structure
is
provided.
A process 100 of making an absorbent article 20 comprises the step of
providing a liquid
permeable topsheet web 240 extending substantially continuously in a machine
direction, the
topsheet web 240 having a first and second surface, a liquid impermeable
backsheet web 2555
extending substantially continuously in the machine direction, and an
acquisition layer 52 having
a first and second surface. In an absorbent article 20, the first surface of
the topsheet 24 will be
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
facing towards the body of the wearer when the absorbent article 20 is in use.
The topsheet web
240 and thus the topsheet 24 and the acquisition layer 52 comprise fibers.
The topsheet web 240 and acquisition layer 52 are aligned in a face to face
relationship
such that the second surface of the topsheet web 240 is in contact with the
first surface of the
5 acquisition layer 52. The topsheet web 240 and the acquisition layer 52
are simultaneously
mechanically deformed and combined together to provide a topsheet/acquisition
layer laminate
web 2450 having three-dimensional protrusions 250. This means that both
topsheet web 240 and
acquisition layer 52 are mechanically deformed and combined together at the
same time.
The three-dimensional protrusions 250 are formed from the fibers of the
topsheet web
240 and the acquisition layer 52. A majority of the three-dimensional
protrusions 250 each
comprises a base 256 forming an opening and having a protrusion base width, an
opposed distal
portion 257, and one or more side walls 255 between the base 256 and the
distal portion 257 of
the majority of the three-dimensional protrusions. The base 256, distal
portion 257 and the one or
more side walls 255 are formed by fibers such that the majority of the three-
dimensional
protrusions 250 has only an opening at the base, as e.g. shown in Fig. 18A.
The majority of the
three-dimensional protrusions 250 can be obtained by the mechanical process
described in detail
below.
The majority of the three-dimensional protrusions 250 may be more than 50% or
more
10 than 60% or more than 70% or more than 80% or more than 90% or more than
95% or more than
98% of the three-dimensional protrusions 250 in the topsheet/acquisition layer
laminate web
2450 or in the topsheet/acquisition layer laminate 245.
The fibers may substantially or completely surround the one or more side walls
255 of the
majority of the three-dimensional protrusions 250. This means that there are
multiple fibers
which contribute to form a portion of the side walls 255 and distal portion
257 of a three-
dimensional protrusion 250. The term "substantially surround" does not require
that each
individual fiber be wrapped substantially or completely around the side walls
255 of the majority
of the three-dimensional protrusions 250.
The topsheet/acquisition layer laminate web 2450 has a first surface
comprising the
second surface of the acquisition layer 52.
15 A portion of the backsheet web 2555 is joined to a portion of the
topsheet web 240 of the
topsheet/acquisition layer laminate web 2450 such that the first surface of
the
topsheet/acquisition layer laminate 2450 is facing towards the backsheet web
2555.
The process 100 of making an absorbent article 20 may comprise the step of
providing a
dry-laid fibrous structure or a wet-laid fibrous structure, as shown in Fig.
8.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
21
As shown in Fig. 8, the topsheet web 240 and acquisition layer 52 are
mechanically
deformed and combined between a first and second roll (211, 212) to form a
topsheet/acquisition
layer laminate web 2450. Dry-laid fibers 540 of a dry-laid fibrous structure
(as shown in Fig. 8,
provided from a distribution material feeder 210) or a wet-laid fibrous
structure may be deposited
on the first surface of the topsheet/acquisition layer laminate web 2450 or
the backsheet web
2555.
A portion of the backsheet web 2555 may be joined to a portion of the topsheet
web 240
of the topsheet/acquisition layer laminate web 2450 such that the dry-laid
fibrous structure or the
wet-laid fibrous structure are between the topsheet/acquisition layer laminate
web 2450 and the
backsheet web 2555.
The dry-laid fibrous structure may comprise dry-laid fibers. The dry-laid
fibrous structure
may comprise a mixture including superabsorbent polymers (SAP) and dry-laid
fibers. The dry-
laid fibers may comprise intra-fiber cross-linked cellulosic fibers.
The distribution layer may be free of tow fibers.
The distribution layer 54 may for example comprise at least 50% by weight of
cross-
linked cellulose fibers. The cross-linked cellulosic fibers may be crimped,
twisted, or curled, or a
combination thereof including crimped, twisted, and curled. This type of
material has been used
in the past in disposable diapers as part of an acquisition system, for
example US 2008/0312622
Al (Hundorf).
Exemplary chemically cross-linked cellulosic fibers suitable for a
distribution layer 54 are
disclosed in US 5,549,791; US 5,137,537; W095/34329 or U52007/118087.
Exemplary cross-
linking agents may include polycarboxylic acids such as citric acid and/or
polyacrylic acids such
as acrylic acid and maleic acid copolymers.
The distribution layer may typically have an average basis weight of from 30
to 400 g/m2,
in particular from 100 to 300 g/m2. The density of the distribution layer may
vary depending on
the compression of the article, but may be of between 0.03 to 0.15 g/cm3, in
particular 0.08 to
0.10 g/cm3 measured at 0.30 psi (2.07kPa).
The process may comprise the step of providing an absorbent core 28 which
comprises an
absorbent material 60. The absorbent material 60 may comprise from 80% to 100%
of SAP, such
as SAP particles, by total weight of the absorbent material 60.
Another type of absorbent material may be water-absorbing foams based on cross-
linked
monomers comprising acid groups, see for example from EP 0 858 478 B 1, WO
97/31971 Al,
WO 99/44648 Al and WO 00/52087 Al.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
22
Hence, the first surface of the topsheet/acquisition layer laminate web 2450
can carry the
material of the distribution layer 54 or the absorbent material 60 of the
absorbent core 28.
The absorbent article 20 may comprise gasketing cuffs 32. The majority of the
three-
dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 may
at least be
present in the acquisition layer 52 and in the topsheet 24, in the area where
the topsheet 24
overlaps the acquisition layer 52 in the topsheet/acquisition layer laminate
245. However, the
majority of the three-dimensional protrusions 250 of the topsheet/acquisition
layer laminate 245
may be present in the area which extends parallel to the transversal axis 90
of the absorbent
article 20. The majority of the three-dimensional protrusions 250 of the
topsheet/acquisition layer
laminate 245 may be present in the area which extends parallel to the
longitudinal axis 80 of the
absorbent article 20, but which does not extend beyond the area where
gasketing cuffs 32 is
attached to the absorbent article 20, in particular to the topsheet 24, as
shown in Fig. 2 or 3. In
that case, the majority of the three-dimensional protrusions 250 which are
formed in the topsheet
24 of the topsheet/acquisition layer laminate 245, are formed from the fibers
of the topsheet 24.
Alternatively, the majority of the three-dimensional protrusions 250 of the
topsheet/acquisition layer laminate 245 may be present in the acquisition
layer and in the
topsheet in the area which extends parallel to the transversal axis 90 of the
absorbent article 20
such that the area comprising the three-dimensional protrusions of the
topsheet 24 overlaps the
acquisition layer 52. The length of the area of the majority of the three-
dimensional protrusions
250 of the topsheet/acquisition layer 245 may be from 5% to 60% or from 10% to
40% wider
than the length of the acquisition layer 52 of the topsheet/acquisition layer
laminate 245. The
majority of the three-dimensional protrusions 250 of the topsheet/acquisition
layer 245 may be
present in the area which extends parallel to the longitudinal axis 80 of the
absorbent article 20
such that the area comprising the three-dimensional protrusions of the
topsheet 24 overlaps the
acquisition layer 52. The width of the area of the majority of the three-
dimensional protrusions
250 of the topsheet/acquisition layer 245 may be from 5% to 60% or from 10% to
40% wider
than the width of the acquisition layer 52 of the topsheet/acquisition layer
laminate 245. In that
case, the majority of the three-dimensional protrusions 250 which are formed
in the topsheet 24
of the topsheet/acquisition layer laminate 245, are formed from the fibers of
the topsheet 24.
In still another alternative, the majority of the three-dimensional
protrusions 250 of the
topsheet/acquisition layer laminate 245 may only be present where the topsheet
24 overlaps the
acquisition layer 52 in the topsheet/acquisition layer laminate 245, as shown
in Fig. 4.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
23
Hence, the three-dimensional protrusions 250 can provide an impression of
depth and can
support the caregiver's perception that the absorbent article 20 is well able
to absorb the liquid
bodily exudates.
The majority of the three-dimensional protrusions 250 of the
topsheet/acquisition layer
laminate 245 may have a measured protrusion height from 0.3 mm to 5 mm or from
0.5 mm to 3
mm or from 1.0 mm to 2.0 mm according to the Protrusion Height Test Method as
described
below. The majority of the three-dimensional protrusions 250 of the
topsheet/acquisition layer
laminate 245 may have a measured protrusion base width of the three-
dimensional protrusions
250 from 0.5 mm to 10 mm or from 0.5 to 5 mm or from 0.5 mm to 3.0 mm or from
1.0 mm to
2.5 mm or from 1.5 mm to 2.5 mm according to the Protrusion Base Width Test
Method as
described below. The majority of the three-dimensional protrusions 250 having
a shape with a
specific measured protrusion height and measured protrusion base width can
contribute to
provide an impression of depth and can support the caregiver's perception that
the absorbent
article 20 is well able to absorb the liquid bodily exudates.
These three-dimensional protrusions 250 provide void volume to receive the
liquid bodily
exudates. At the same time, the topsheet/acquisition layer laminate 245 is in
close contact with
the underlaying layer, i.e. the distribution layer 54. The distribution layer
54 made of
unconsolidated fibers 540 of the dry-laid fibrous structure or the wet-laid
fibrous structure may
sink in the depressions provided by the three-dimensional protrusions 250 of
the
topsheet/acquisition layer laminate 245 (not shown in the schematic Figures).
The distribution
layer 54 may follow the shape of the three-dimensional protrusions. Hence, the
liquid bodily
exudates are transmitted more efficiently from the topsheet/acquisition layer
laminate 245 to the
distribution layer 54, which can improve the dryness of the topsheet 24 of the
topsheet/acquisition layer laminate 245. Rewet can be reduced at the skin of
the wearer. The
topsheet/acquisition layer laminate 245 may also enable more efficient use of
an absorbent core
28. Overall, the topsheet 24 of the topsheet/acquisition layer laminate 245
can have an improved
dryness than a three-dimensional topsheet 24 placed on top of an acquisition
layer 52.
The majority of the three-dimensional protrusions 250 may comprise void areas
253
which do not contact the skin of the wearer. The absorbent article 20 may be
in less contact with
the skin of the wearer in comparison with a flat topsheet. The void areas 253
of the
topsheet/acquisition layer laminate 245 can help the air to permeate between
the skin of the
wearer and the topsheet/acquisition layer laminate 245. The void areas 253 of
the
topsheet/acquisition layer laminate 245 can improve the breathability of the
topsheet/acquisition
layer laminate 245.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
24
In addition to improve dryness, the void areas 253 of the topsheet/acquisition
layer
laminate 245 can also allow feces to be absorbed and acquired within them. In
that case, the
present invention is suitable to absorb feces of relatively low viscosity.
A width of the acquisition layer 52 is less than a width of the topsheet web
240 in a cross
direction. In the absorbent article 20 comprising the longitudinal axis 80 and
the transversal axis
90 perpendicular to the longitudinal axis 80, the width of the acquisition
layer 52 in a direction
parallel to the transversal axis 90 is less than the width of the topsheet 24
in a direction parallel to
the transversal axis 90. If the width of both topsheet 24 and acquisition
layer 52 were the same,
wicking of the liquid bodily exudates underneath the gasketing cuffs 32 might
occur. Hence, the
liquid bodily exudates might not be properly absorbed by the absorbent core
28, which may lead
to leakage of the liquid bodily exudates out of the absorbent article 20. If
the width of the
acquisition layer 52 in a direction parallel to the transversal axis 90 is
less that the width of the
topsheet 24 in a direction parallel to the transversal axis 90, the
acquisition layer 52 which may
receive the liquid bodily exudates from the topsheet 24 can directly transmit
the liquid bodily
exudates to the distribution layer 54 in order to be subsequently absorb by
the absorbent core 28.
Hence, the liquid bodily exudates temporary stored in the acquisition layer 52
of the
topsheet/acquisition layer laminate 245 will not readily be drawn towards and
underneath the
gasketing cuffs 32 by capillary forces. Leakage can thus be reduced by having
the width of the
acquisition layer 52 in a direction parallel to the transversal axis 90 less
that the width of the
topsheet 24 in the topsheet/acquisition layer laminate 245 in a direction
parallel to the transversal
axis 90.
In order to help reducing leakage and rewet, the width of the acquisition
layer 52 in a
direction parallel to the transversal axis 90 of the topsheet/acquisition
layer laminate 245 may not
be more than 40% wider than the width of the distribution layer 54 and/or more
than 20% wider
than the width of the absorbent core 28 in a direction parallel to the
transversal axis 90. In that
case, the liquid bodily exudates may not accumulate at or adjacent to the
transversal edges of the
acquisition layer 52. Wicking of the liquid bodily exudates underneath the
gasketing cuffs 32 is
prevented. Indeed, when the acquisition layer 52 of the tospheet/acquisition
layer laminate 245 is
no more than 20% wider than the width of the absorbent core 28, the liquid
bodily exudates can
readily be transported into the absorbent core 28, which can efficiently drain
the fluid from the
acquisition layer 52 into the absorbent core 28. Wicking of the liquid bodily
exudates form the
acquisition layer 52 underneath the gasketing cuffs 32 is prevented.
The acquisition layer 52 can receive the liquid bodily exudates that pass
through the
topsheet 24 and can distribute them to underlying absorbent layers. In such a
case, the topsheet
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
24 in the topsheet/acquisition layer laminate 245 may be less hydrophilic than
the acquisition
layer 52. The topsheet 24 of the topsheet/acquisition layer laminate 245 can
be readily dewatered.
In order to enhance dewatering of the topsheet 24 of the topsheet/acquisition
layer
laminate 245, the pore size of the acquisition layer 52 may be reduced. For
this, the acquisition
5 layer 52 may made of fibers with relatively small denier. The acquisition
layer 52 may also have
an increased density.
The process may comprise the step of joining the portion of the backsheet web
2555 to
the portion of the topsheet web 240 at or adjacent to the transversal edges of
the first surface of
the topsheet/acquisition layer laminate web 2450 in the cross direction. The
transversal edges of
10 the first surface of the topsheet/acquisition layer laminate web 2450 do
not comprise any
acquisition layer 52. When the portion of the backsheet web 2555 is joined to
the portion of the
topsheet web 240 of the topsheet/acquisition layer laminate web 2450, the
acquisition layer 52 is
then enveloped between the topsheet web 240 and the backsheet web 2555.
The process may comprise the step of cutting into individual absorbent
articles
15 comprising a backsheet 25, a topsheet 24 and an acquisition layer 52,
characterized in that the
topsheet 24 and acquisition layer 52 are joined to form a topsheet/acquisition
layer laminate 245.
The topsheet/acquisition layer laminate web 2450 may be produced at a
particular
location in the process setup. Hence, the topsheet/acquisition layer laminate
web 2450 might be
not available to carry the dry-laid fibrous structure of the distribution
layer 54 at the desired
20 location of the process.
A process of making an absorbent article comprises the step of providing a
liquid
permeable topsheet web 240 extending substantially continuously in a machine
direction, the
topsheet web 240 having a first and second surface, a liquid impermeable
backsheet web 2555
extending substantially continuously in the machine direction, an acquisition
layer 52 having a
25 first and second surface, a dry-laid fibrous structure and a carrier
layer web 170 having a first and
second surface (171, 172), as shown in Figs. 9 and 10. The topsheet web 240
and the acquisition
layer 52 comprise fibers.
The topsheet web 240 and acquisition layer 52 are aligned in a face to face
relationship
with the acquisition layer 52 such that the second surface of the topsheet web
240 is in contact
with the first surface of the acquisition layer 52. The topsheet web 240 and
the acquisition layer
52 are simultaneously mechanically deformed and combined together to provide a
topsheet/acquisition layer laminate web 2450 having three-dimensional
protrusions 250.
The three-dimensional protrusions 250 are formed from the fibers of the
topsheet web
240 and the acquisition layer 52. A majority of the three-dimensional
protrusions 250 each
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
26
comprises a base 256 forming an opening, an opposed distal portion 257, and
one or more side
walls 255 between the base 256 and the distal portion 257 of the majority of
the three-
dimensional protrusion 250. The base 256, distal portion 257 and one or more
side walls 255 are
formed by fibers such that the majority of the three-dimensional protrusions
250 has only an
opening at the base 256. At least 50% or at least 80% of the three-dimensional
protrusions 250 of
the topsheet/acquisition layer laminate 245 may only have openings at the base
256. The majority
of the three-dimensional protrusions 250 may be obtained by the mechanical
process described in
detail below.
The topsheet/acquisition layer laminate web 2450 has a first surface
comprising the
second surface of the acquisition layer 52.
The fibers 540 of the dry-laid fibrous structure are deposited on the first
surface 171 of
the carrier layer web 170 as shown in Figs. 9 and 10. A portion of the
backsheet web 2555 is
joined to a portion of the topsheet web 240 of the topsheet/acquisition layer
laminate 2450 such
that the second surface 172 of the carrier layer web 170 is facing the
topsheet/acquisition layer
laminate web 2450 or the backsheet web 2555.
Hence, the carrier layer web 170 can carry out the material of the
distribution layer 54
wherever the topsheet/acquisition layer laminate web 2450 is produced and
provided in the
process.
According to the method used for making the three-dimensional structure of the
topsheet/acquisition layer laminate web 2450, when the topsheet web 240 and
acquisition layer
52 are mechanically deformed together, holes might unintentionally occur. When
the distribution
layer 54 comprises the dry-laid fibrous structure, the fibers 540 of the dry-
laid fibrous structure
may pass through the unintentional holes formed at the resulting
topsheet/acquisition layer
laminate 245 and contact undesirably the skin of the wearer. It may be
desirable to prevent that
the fibers 540 of the dry-laid fibrous structure can pass through the
unintentional holes of the
resulting topsheet/acquisition layer laminate 245.
The carrier layer web 170 may be disposed between the topsheet/acquisition
layer
laminate web 2450 and the dry-laid fibrous structure, as shown in Fig. 9. In
the absorbent article
20, the carrier layer 17 may act as a barrier layer to impede the fibers 540
of the dry-laid fibrous
structure from passing through the holes of the topsheet/acquisition layer
laminate 245
unintentionally formed by the three-dimensional mechanical deformation of the
topsheet 24 with
the acquisition layer 52, as shown in Figs. 11 and 12(A-B). Also, the carrier
layer 17 may help
the transfer of the liquid bodily exudates from the topsheet/acquisition layer
laminate 245 to the
dry-laid fibrous structure.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
27
The first surface 171 of the carrier layer 17 in the absorbent article 20 may
be attached at
or adjacent to its longitudinal edges to the absorbent core 28. Hence, when
the carrier layer 17 is
disposed between the topsheet/acquisition layer laminate 245 and the dry-laid
fibrous structure,
and the first surface 171 of the carrier layer 17 is attached to the absorbent
core 28, the fibers 540
of the dry-laid fibrous structure may be not able to escape between the
carrier layer 17 and the
absorbent core 28, as exemplified in Fig. 12B. The attachment of the carrier
layer 17 to the
longitudinal edges of the absorbent core 28 may include a uniform continuous
layer of adhesive
173, a discontinuous patterned application of adhesive or an array of separate
lines, spirals, or
spots of adhesive.
Alternatively, the carrier layer web 170 may be disposed between the dry-laid
fibrous
structure and the absorbent core 28, as shown in Fig. 10. Hence, the carrier
layer 17 in the
absorbent article 20 may help to distribute and transfer of the liquid bodily
exudates from the
distribution layer 54 to the absorbent core 28, as shown in Figs. 13 and 14,
which enables more
efficient use of the absorbent core 28.
The carrier layer 17 may be attached at or adjacent to its longitudinal edges
to the first
surface of the topsheet/acquisition layer laminate 245. Hence, when the
carrier layer 17 is
disposed between the dry-laid fibrous structure and the absorbent core 28, and
the carrier layer 17
is attached to the first surface of the topsheet/acquisition layer laminate
245, the fibers 540 of the
dry-laid fibrous structure may be not able to escape between the
topsheet/acquisition layer
laminate 245 and the carrier layer 17. The attachment of the carrier layer 17
to the longitudinal
edges to the first surface of the topsheet/acquisition layer laminate 245 may
include a uniform
continuous layer of adhesive, a discontinuous patterned application of
adhesive or an array of
separate lines, spirals, or spots of adhesive.
The process may comprise the step of cutting into individual absorbent
articles 20
comprising a backsheet 25, a carrier layer 17, a topsheet 24 and an
acquisition layer 52
characterized in that the topsheet 24 and acquisition layer 52 are joined to
form a
topsheet/acquisition layer laminate 245.
The acquisition layer 52 of the topsheet/acquisition layer laminate web 2450
may be
provided continuously in the machine direction. A length of the acquisition
layer 52 of the
topsheet/acquisition layer laminate 245 in a direction parallel to the
longitudinal axis 80 may be
equal of the length of the topsheet 24 in a direction parallel to the
longitudinal axis 80 of the
absorbent article 20.
Alternatively, the acquisition layer 52 of the topsheet/acquisition layer
laminate web 2450
may be provided intermittently in the machine direction. The length of the
acquisition layer 52 of
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
28
the topsheet/acquisition layer laminate 245 in a direction parallel to the
longitudinal axis 80 may
be less than the length of the topsheet 24 in a direction parallel to the
longitudinal axis 80 of the
absorbent article 20, as shown in Fig. 4. When the length of the acquisition
layer 52 in the
topsheet/acquisition layer laminate 245 is less than the length of the
topsheet 24, the liquid bodily
exudates cannot be readily drawn towards the longitudinal edges (10, 12) of
the absorbent article
20, which reduces leakage.
The length of the acquisition layer 52 in the topsheet/acquisition layer
laminate 245 may
be less than the length of the absorbent core 28 taken along the longitudinal
axis 80 of the
absorbent article 20, see for example Fig. 4.
The acquisition layer 52 of the topsheet/acquisition layer laminate 245 may be
positioned
in the front region 36 and at least partially in the crotch region 37 of the
absorbent article 20, as
shown in Fig. 15. In that case, positioning the acquisition layer 52 of the
topsheet/acquisition
layer laminate 245 in the front region 36 of the absorbent article 20 helps
for acquiring and
distributing the liquid bodily exudates such as urine, around the pee point of
the wearer.
The acquisition layer 52 of the topsheet/acquisition layer laminate 245 may be
positioned
in the back region 38 and at least partially in the crotch region 37 of the
absorbent article 20, as
shown in Fig. 16. Positioning the acquisition layer 52 of the
topsheet/acquisition layer laminate
245 in the back region 38 of the absorbent article 20 helps at acquiring the
feces of the wearer,
especially when the feces have a low viscosity.
The majority of the three-dimensional protrusions 250 of the
topsheet/acquisition layer
laminate 245 may protrude towards the backsheet 25 or towards the body of the
wearer when the
absorbent article is in use.
The topsheet/acquisition layer laminate 245 may be notionally divided into a
first and
second area. The first area may comprise three-dimensional protrusions 250
which protrude
towards the backsheet 25. The second area may comprise three-dimensional
protrusions 250
which protrude towards the body of the wearer when the absorbent article is in
use.
For instance, the first area may be located in the front region 36 and at
least partially in
the crotch region 37 of the absorbent article 20.
Having the first area where the three-dimensional protrusions 250 of the
topsheet/acquisition layer laminate 245 protrude towards the backsheet 25 can
help acquiring and
absorbing the liquid bodily exudates to the absorbent core 28. Having the
second area where the
three-dimensional protrusions 250 of the topsheet/acquisition layer laminate
245 protrude
towards the body of the wearer when the absorbent article is in use can
improve cleaning the
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
29
body from the exudates. Hence, a combination of the first and second area can
allow the
absorbent article 20 to better perform.
The topsheet 24 of the topsheet/acquisition layer laminate 245 may be coated
with a
lotion composition. The lotion composition may be located in the areas of the
topsheet 24 which
are between the three-dimensional protrusions 250 of the topsheet/acquisition
layer laminate 245.
Typical lotion compositions used in diapers are disclosed in U.S. Patent No.
6,426,444
B2. The resulting lotion composition may be applied to the
topsheet/acquisition layer laminate by
spraying, printing (e.g., flexographic printing), coating (e.g., contact slot
coating, gravure
coating), extrusion, microencapsulation or combinations of these application
techniques.
The majority of the three-dimensional protrusions 250 may be disposed in any
suitable
arrangement across the plane of the topsheet/acquisition layer laminate 245.
Suitable
arrangements include, but are not limited to: staggered arrangements, and
zones. In some cases,
the topsheet/acquisition layer laminate 245 may comprise both three-
dimensional protrusions 250
and other features known in the art such as embossments and apertures. The
three-dimensional
protrusions 250 and other features may be in separate zones, be intermixed, or
overlap.
Intermixed arrangements can be created in any suitable manner. In some cases,
intermixed
arrangements can be created by using the techniques described in U.S. Patent
Publication No. US
2012/0064298 Al, On, et al. In other cases, overlapping arrangements can be
created by forming
the three-dimensional protrusions 250 and then subsequently passing the
topsheet/acquisition
layer laminate web 2450 between a forming member having male forming elements
thereon and
a compliant surface, and applying pressure to the web with the forming member
and compliant
surface. These techniques for producing overlapping arrangements enable three-
dimensional
protrusions 250 and other features to be combined so they are disposed in
different locations on
the topsheet/acquisition layer laminate 245 or they can cause at least some of
the three-
dimensional protrusions 250 and at least some of the other features
(apertures, embossments) to
be disposed in the same location on the topsheet/acquisition layer laminate
245.
The carrier layer
The carrier layer 17 may be selected from the group consisting of nonwovens,
tissues, or
films and combinations thereof.
Examples of a nonwoven web used for the carrier layer 17 may include various
types of
known nonwoven webs such as a spunbonded nonwoven web, a meltblown nonwoven
web, and
a spunbond-meltblown-spunbond nonwoven web. These nonwoven webs are made of
thermoplastic polymers.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
A material for fibers composing the nonwoven web used for the carrier layer 17
may
include various types of known fibers such as polyethylene, polypropylene,
polyester, and acryl,
conjugate fibers such as polyethylene/polypropylene, polyethylene/polyethylene
terephthalate,
and polypropylene/polyethylene terephthalate, i.e., fibers formed of core-in-
sheath fibers and
5 side-by-side fibers. The fibers may be used alone or in combination.
Further, the carrier layer 17
may have a monolayer structure or a multilayer structure.
The carrier layer 17 may comprise a tissue made of wet-laid fibers comprising
cellulose
fibers having a Wet burst Strength from 50 to 500 g according to the Wet Burst
Strength Test
Method and combinations thereof.
10 The carrier layer 17 may be treated with a surfactant to render the
carrier layer 17
hydrophilic. The carrier layer 17 may be made of one material of the group as
set out above,
which has been chemically modified to render it hydrophilic. The hydrophilic
carrier layer 17
may thus improve the transfer of the liquid bodily exudates from the
distribution layer 54 to the
absorbent core 28 of the absorbent article 20.
15 The carrier layer 17 may have a basis weight of at least 5 gsm to 60 gsm
or at least 5 gsm
to 20 gsm or at least 5 to 15 gsm.
The carrier layer 17 may be wider and longer than the distribution layer 54.
The carrier
layer can help preventing the fibers 540 of the dry-laid fibrous structure
getting to the skin of the
wearer when the distribution layer 54 comprises the dry-laid fibrous structure
and if the
20 topsheet/acquisition layer laminate 245 comprises some holes.
The carrier layer 17 may be colored. The process may comprise the step of
providing the
carrier layer web 170 which is colored. Color may be imparted to the carrier
layer 17 by color
pigmentation. The term "color pigmentation" encompasses any pigments suitable
for imparting a
non-white color to the carrier layer 17. This term therefore does not include
"white" pigments
25 such as TiO2 which are typically added to the layers of conventional
absorbent articles to impart
them with a white appearance. Pigments are usually dispersed in vehicles or
substrates for
application, as for instance in inks, paints, plastics or other polymeric
materials.
The pigments may for example be introduced in a polypropylene masterbatch. A
masterbatch comprises a high concentration of pigment and/or additives which
are dispersed in a
30 carrier medium which can then be used to pigment or modify the virgin
polymer material into a
pigmented bicomponent nonwoven. An example of suitable colored masterbatch
material that
can be introduced is Pantone color 270 Sanylen violet PP 42000634 ex Clariant,
which is a PP
resin with a high concentration of violet pigment. Typically, the amount of
pigments introduced
by weight of the carrier layer 17 may be of from 0.3% - 2.5%.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
31
Alternatively, color may be imparted to the carrier layer 17 by way of
impregnation of a
colorant into the substrate. Colorants such as dyes, pigments, or combinations
may be
impregnated in the formation of substrates such as polymers, resins, or
nonwovens. For example,
the colorant may be added to molten batch of polymer during film, fiber, or
filament formation.
When viewing the absorbent article 20 from the topsheet 24, the colored
carrier layer 17
may provide to a caregiver an enhanced impression of depth to support to the
impression given
by the three-dimensional protrusions 250 as such, as long as the colored
carrier layer 17 are
visible from the topsheet 24. Hence, a colored carrier layer 17 can support
the caregiver's
perception that the absorbent article 20 is well able to absorb the liquid
bodily exudates.
The topsheet 24 and /or acquisition layer 52 of the topsheet/acquisition layer
laminate 245
may be colored, for the same reasons.
The carrier layer 17 may be porous, may have a relatively high permeability
and have a
relatively high level of saturation when exposed to fluid at suction pressures
such as 20 cm water.
The relatively high level of saturation of the carrier layer 17 can be defined
as the ratio between
the volume of liquid bodily exudates in the pores of the carrier layer 17 and
the total void volume
of the carrier layer 17. The carrier layer 17 can help providing connectivity
between the
acquisition layer 52 of the topsheet/acquisition layer laminate 245 and the
distribution layer 54.
Also, the carrier layer 17 may comprise some relative small sized holes such
that the
fibers 540 of the dry-laid fibrous structure of the distribution layer 54 may
partially pass through
the holes of the carrier layer. Hence, the fibers 540 of the dry-laid fibrous
structure can entangle
and contact the acquisition layer 52 of the topsheet/acquisition layer
laminate 245. The carrier
layer 17 may comprise holes having a size from 0.02 mm to 10 mm.
The mechanical deformations and the resulted three-dimensional protrusions
The step of the process 100 related to mechanically deforming and combining
the
topsheet 24 with the acquisition layer 52 may comprise the following step of
providing a first and
second forming member (211, 212) having a machine direction and a cross
direction orientation,
as shown in Figs. 17A, 17B and 17C. The first and second forming member (211,
212) may be
drum-shaped, generally cylindrical or plate-shaped.
The first forming member 211 of the apparatus 200 may have a surface
comprising a
plurality of discrete, spaced apart male forming elements 213 having a base
that is joined to the
first forming member 211, a top that is spaced away from the base, and sides
that extend between
the base and the top of the male forming elements 213. The male forming
elements 213 may have
a plan view periphery, and a height.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
32
The top on the male forming elements 213 may have a rounded diamond shape, see
for
example Fig. 17A, with vertical sidewalls and a radiused or rounded edge at
the transition
between the top and the sidewalls of the male forming element 213.
The second forming member 212 may have a surface comprising a plurality of
recesses
214 in the second forming member 212. The recesses 214 may be aligned and
configured to
receive the respective male forming elements 213 therein. Hence, each recess
214 of the second
forming member 212 may be sufficiently large to be able to receive each
respective male forming
element 213 of the first forming member 211. The recesses 214 may have a
similar shape as the
male forming elements 213. The depth of the recesses 214 may be greater than
the height of the
male forming elements 213.
The first and second forming member (211, 212) may be further defined by a
depth of
engagement (DOE) which is a measure of the level of intermeshing of the first
and second
forming member (211, 212), as shown in Fig. 17C. The depth of engagement (DOE)
may be
measured from the tip of the male forming elements 213 to the outermost
portion of the surface
of the second forming member 212 which portions are not within a recess 214.
The depth of
engagement (DOE) may range from 1.5 mm to 5.0 mm or from 2.5 mm to 5.0 mm or
from 3.0
mm to 4.0 mm.
The first and second forming member (211, 212) may be defined by a clearance
between
the first and second forming member (211, 212) as shown in Fig. 17C. The
clearance is the
distance between the side wall of the male forming element 213 and the side
wall of the recess
214. The clearance may range from 0.1 mm to 2 mm or from 0.1 mm to 1.5 mm from
0.1 mm to
1 mm.
The topsheet 24 and the acquisition layer 52 may be engaged together between
the first
and second forming members (211, 212) and be mechanically deformed and
combined together
to form the topsheet/acquisition layer laminate 245. The topsheet/acquisition
layer laminate 245
comprises thus deformations forming three-dimensional protrusions 250.
The topsheet/acquisition layer laminate 245 may be notionally divided into a
first and
second area. The first and/or second area of the topsheet/acquisition layer
laminate 245 may
comprise the majority of the three-dimensional protrusions 250 having
different shapes.
Viewed from a cross-sectional view, i.e. in a Z-direction, the majority of the
three-
dimensional protrusions 250 may have any suitable shapes which include, but
are not limited to:
bulbous-shaped, conical-shaped and mushroom shaped.
Viewed from above, the majority of the three-dimensional protrusions 250 may
have any
suitable shapes which include, but are not limited to: circular, diamond-
shaped, round diamond-
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
33
shaped, U.S. football-shaped, oval-shaped, clover-shaped, triangular-shaped,
tear-drop shaped
and elliptical-shaped protrusions. The majority of the three-dimensional
protrusions 250 may be
non-circular.
The majority of the three-dimensional protrusions 250 may form, in
conjunction, one or
more graphics. Having graphics can support the caregiver' s perception that
the absorbent article
is well able to absorb the liquid bodily exudates.
Also, the majority of the three-dimensional protrusions 250 may form, in
conjunction,
one or more graphics such as a logo, e.g. the Pampers Heart logo.
The majority of the three-dimensional protrusions 250 may have similar plan
view
dimensions in all directions, or the majority of the three-dimensional
protrusions 250 may be
longer in one dimension than another. The majority of the three-dimensional
protrusions 250 may
have different length and width dimensions. The majority of the three-
dimensional protrusions
250 may, thus, have a ratio of length to width. The ratio of length to width
can range from 10:1 to
1:10.
The topsheet/acquisition layer laminate 245 may comprise a plurality of three-
dimensional protrusions 250 which may extend towards the distribution layer 54
(see also Fig. 2)
or towards the carrier layer 17 (see Figs. 11, 12). When the majority of the
three-dimensional
protrusions 250 extend towards the distribution layer 54, the area of contact
between the
acquisition layer 52 of the topsheet/acquisition layer laminate 245 and the
underneath distribution
layer 54 is improved. The distribution layer 54 will follow the shape of the
majority of the three-
dimensional protrusions 250. Hence, the transfer of the liquid bodily exudates
from the
topsheet/acquisition layer laminate 245 to the distribution layer 54 can be
increased.
Fig. 18A-Fig. 18F shows different alternatives of three-dimensional
protrusions 250. A
bulbous-shaped protrusion may be one type of three-dimensional protrusions 250
which may be
obtained by the process step described above using the apparatus 200. The
topsheet/acquisition
layer laminate 245 may comprise the majority of the of three-dimensional
protrusions 250
protruding towards the backsheet 25.
As shown in Fig. 18A, the three-dimensional protrusion 250 is formed from the
fibers of
the topsheet 24 and the acquisition layer 52. The three-dimensional protrusion
250 is defined by a
base 256 forming an opening and having a protrusion base width, an opposed
enlarged distal
portion 257 that extends to a distal end 259 and one or more side walls 255
between the base 256
and the distal portion 257. The base 256, distal portion 257 and the one or
more side walls 255
are formed by fibers such that the three-dimensional protrusion 250 has only
an opening at the
base 256, as shown in Fig. 18A. The side wall 255 may be substantially
continuous. For instance,
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
34
the side wall 255 may be spherical or conical. The three-dimensional
protrusion 250 may
comprise more than one side wall 255, e.g. in a pyramidal-shaped protrusion.
The fibers may
substantially or completely surround the one or more side walls 255 of the
three-dimensional
protrusions 250.
As shown in Fig. 18B, a three-dimensional protrusion 250 comprising an inner
and outer
three-dimensional protrusion 251A and 251B may be made from engaging the
topsheet web 240
with the acquisition layer 52 between the first and second forming member
(211, 212) such as the
inner three-dimensional protrusion 251A from the topsheet 24 and the outer
three-dimensional
protrusion 251B from the acquisition layer 52 coincide with and fit together.
Hence, as shown in
Fig. 18B, the inner three-dimensional protrusion 251A of the topsheet 24 and
the outer three-
dimensional protrusion 251B of the acquisition layer 52 are nested together.
The inner three-dimensional protrusion 251A may comprise a plurality of fibers
254A
which constitutes the topsheet 24. The outer three-dimensional protrusion 251B
in which the
inner three-dimensional protrusion 251A may be nested, may comprise a
plurality of fibers 254B
which constitutes the acquisition layer 52. The plurality of fiber (254A,
254B) composing the
three-dimensional protrusion 250 may surround the side walls 255 of the three-
dimensional
protrusions 250.
The topsheet 24 and the acquisition layer 52 may be both extensible. The
fibers
composing the topsheet 24 and acquisition layer 52 may elongate and/or may be
mobile, such
that the topsheet 24 and acquisition layer 52 are able to stretch to be nested
together.
Generally, the extensibility of the materials composing the topsheet 24 and
acquisition
layer 52 can be selected according to the desired sizes of the three-
dimensional protrusions 250.
If relatively large three-dimensional protrusions 250 are desired, materials
with a relatively
higher extensibility will be chosen.
For instance, the topsheet 24 or acquisition layer 52 may be capable of
undergoing an
apparent elongation of equal to or greater than at least 100% or 110% or 120%
or 130% up to
200% in the machine and/or cross-machine directions at or before reaching the
breaking force
according to the Test Method as set out in the Definition part.
In some cases, it might be desired to have three-dimensional protrusions 250
which are
larger either in the machine or cross-machine direction. For this, the
materials composing the
topsheet 24 and acquisition layer 52 can be thus more extensible in either
machine versus cross-
machine direction or vice versa.
The majority of the three-dimensional protrusions 250 may comprise a void area
253
which is the portion of the three-dimensional protrusion 251A which does not
comprise any
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
fibers or very little fibers. The majority of the three-dimensional
protrusions 250 may be defined
by a protrusion base width WB1 of the base 256 forming an opening which is
measured from two
side walls of the inner portion 251A at the base 256. The majority of the
three-dimensional
protrusions 250 may be defined by a width WD2 of the void area 253 which is
the maximum
5
interior width measured between two side walls of the inner three-dimensional
protrusion 251A
or which is the maximum diameter of the side wall when the distal portion has
a substantially
circular shape. The maximum interior width WD2 of the void area 253 at the
distal portion may
be greater than the protrusion base width WB1 of the base 256 of the majority
of the three-
dimensional protrusions 250. This is the case for some types of three-
dimensional shapes, such as
10
bulbous shapes as exemplified in Fig. 18B but nor for conical shape. The
protrusion base width
protrusion base WB1 of the base 256 of the three-dimensional protrusion 250
may range from 1.5
mm to 15 mm or from 1.5 mm to 10 mm or from 1.5 mm to 5 mm or from 1.5 mm to 3
mm.
Measurements of the dimensions of the protrusion base width WB1 of the base
256 and the width
WD2 of the distal portion 257 can be made on a photomicrograph.
15 When
the size of the protrusion base width WB1 of the base 256 is specified herein,
it will
be appreciated that if the openings are not of uniform width in a particular
direction, the
protrusion base width, WB1, is measured at the widest portion. Measurements of
the width
protrusion base WB1 of the base 256 or the maximum interior width WD2 of the
void area 253 at
the distal portion 257 can be made on a photomicrograph at 20X magnification.
As the plurality of fiber (254A, 254B) composing the majority of the three-
dimensional
protrusions 250 may be present in the one or more side walls 255 of the
majority of the three-
dimensional protrusions 250, the majority of the three-dimensional protrusions
250 may not
collapse on one side and close off the opening at the base 256 when
compressive forces are
applied on the topsheet/acquisition layer laminate 245. The opening at the
base 256 may be
maintained and may create a ring of increased opacity around the opening at
the base 256 when
the three-dimensional protrusions 250 has been compressed. Hence, the majority
of the three-
dimensional protrusion 250 can be preserved and remain visible to the consumer
when viewing
the absorbent article 20 from the topsheet 24. The majority of the three-
dimensional protrusions
250 can be preserved after being subjected to any inherent compressive forces
due to the process
or the step of compressing the absorbent articles comprising the
topsheet/acquisition layer
laminate 245 prior to be filled in a packaging.
20 In
other words, the majority of the three-dimensional protrusions 250 may have a
degree
of dimensional stability in the X-Y plane when a Z-direction force is applied
to the majority of
the three-dimensional protrusions 250. It is not necessary that the collapsed
configuration of the
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
36
majority of the three-dimensional protrusions 250 be symmetrical, only that
the collapsed
configuration prevent the majority of the three-dimensional protrusions 250
from flopping over
or pushing back into the original plane of the topsheet/acquisition layer
laminate 245. Without
wishing to be bound to any particular theory, the wide base 256 and large cap
52 (greater than the
protrusion base width of the base opening 256), combined with the lack of a
pivot point, causes
the three-dimensional protrusions 250 to collapse in a controlled manner (the
large distal portion
257 prevents the three-dimensional protrusion 250 from flopping over and
pushing back into the
original plane of the topsheet/acquisition layer laminate 245). Thus, the
majority of the three-
dimensional protrusions 250 are free of a hinge structure that would otherwise
permit them to
fold to the side when compressed.
It may be desirable for at least one of the three-dimensional protrusions 250
in the
topsheet/acquisition layer laminate 245 to collapse in a controlled manner
described below under
the 7 kPa load when tested in accordance with the Accelerated Compression
Method in the Test
Methods section below.
Alternatively, at least some, or in other cases, a majority of the three-
dimensional
protrusions 250 may collapse in the controlled manner described herein.
Alternatively, substantially all of the three-dimensional protrusions 250 may
collapse in
the controlled manner described herein. The ability of the three-dimensional
protrusions 250 to
collapse may also be measured under a load of 35 kPa. The 7 kPa and 35 kPa
loads may simulate
manufacturing and high compression packaging conditions. Wear conditions can
range from 2
kPa or less up to 7 kPa.
Generally, the majority of the three-dimensional protrusions 250 may be
configured to
collapse in a controlled manner such that each base 256 forming an opening
remains open, and
the protrusion base width of each base 256 forming an opening is greater than
0.5 mm after
compression.
In the area of the three-dimensional protrusions 250, the topsheet 24 and/or
acquisition
layer 52 may comprise one or more interruptions. The formation of the one or
more interruptions
may be due to the properties of the topsheet 24 and acquisition layer 52. The
topsheet 24 may
less extensible with regard to fiber mobility and/or fiber extensibility than
the acquisition layer
52 or vice versa such that a hole starts to form in the topsheet 24 and/or
acquisition layer 52.
As shown in Fig. 18C, the acquisition layer 52 may be interrupted in the area
of the three-
dimensional protrusion 250 of the topsheet/acquisition layer laminate 245.
Generally, the acquisition layer 52 may have a lower extensibility than the
topsheet 24. In
such cases, the acquisition layer 52 may start to rupture and form an
interruption, i.e. the fibers
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
37
composing the acquisition layer 52 may be less extensible and/or mobile than
the fibers
composing the topsheet 24.
The three-dimensional protrusion 251A made of the respective other non-
interrupted
topsheet interpenetrates the interrupted acquisition layer 52. In such case,
the interruptions may
be formed by locally rupturing the acquisition layer 52 by the process
described in detail above.
The interpenetration may be achieved by pushing the topsheet web 240 through
the acquisition
layer 52. In order to obtain these three-dimensional protrusions, the depth of
engagement (DOE)
of the apparatus 200 may be adequately selected from 2 to 10 mm, or from 3 to
7 mm. The
interrupted acquisition layer 52 may have any suitable configuration in the
area of the three-
dimensional protrusion 250. The rupture may involve a simple splitting open of
the acquisition
layer 52 such that the interruption in the acquisition layer 52 remains a
simple two-dimensional
hole. It might happen that a portion of the acquisition layer 52 in the area
of the three-
dimensional protrusion 250 may be slightly deflected or urged out-of-place to
form flaps 269.
When the respective other non-interrupted topsheet 24 interpenetrates the
interrupted
acquisition layer 52, the topsheet 24 can be brought in direct contact with
the underlying layer,
e.g. the carrier layer 17, the distribution layer 54 or the absorbent core 28
leading to an efficient
topsheet dewatering, which can improve the dryness of the topsheet/acquisition
layer laminate
245.
Alternatively, as shown in Figs. 18D or 18E, the acquisition layer 52 may be
interrupted
in in the area of the three-dimensional protrusion 250 of the
topsheet/acquisition layer laminate
245. The three-dimensional protrusion 251B of the interrupted acquisition
layer 52 may comprise
an interruption (258B). The three-dimensional protrusion 251A of the non-
interrupted topsheet
24 may coincide with and fit together with the three-dimensional protrusion
251B of the
interrupted acquisition layer, as shown in Fig. 18D. In other words, the
topsheet 24 is not pushed
through the acquisition layer 52 such that the topsheet 24 does not
interpenetrate through the
acquisition layer 52.
Alternatively, the three-dimensional protrusion 251A of the non-interrupted
topsheet 24
may partially fit together with the three-dimensional protrusion 251B of the
interrupted
acquisition layer, as shown in Fig. 18E.
Likewise, the topsheet 24 may be interrupted in the area of the three-
dimensional
protrusion 250 of the topsheet/acquisition layer laminate 245.
Generally, the topsheet 24 may have a lower extensibility than the acquisition
layer 52. In
such cases, the topsheet 24 may start to rupture and form an interruption,
i.e. the fibers
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
38
composing the topsheet 24 may be less extensible and/or mobile than the fibers
composing the
acquisition layer 52.
In another alternative, the topsheet 24 and acquisition layer 52 may be
interrupted in the
area of the three-dimensional protrusions 250 of the topsheet/acquisition
layer laminate 245 and
the three-dimensional protrusions of the topsheet 251A coincide with and fit
together with the
three-dimensional protrusions 251B of the acquisition layer. The interruptions
258A in the
topsheet 24 in the area of the three-dimensional protrusions 250 of the
topsheet/acquisition layer
laminate 245 will not coincide with the interruptions 258B in the acquisition
layer 52 in the area
of the three-dimensional protrusions 250 of the topsheet/acquisition layer
laminate 245, as shown
in Fig. 18F. In this case, the interruptions (258A, 258B) in the topsheet 24
and acquisition layer
52 are in different locations in the three-dimensional protrusions 250.
The majority of the three-dimensional protrusions 250 may protrude towards the
body of
the wearer when the absorbent article 20 is in use (see also Fig. 3). When the
majority of the
three-dimensional protrusions 250 protrude towards the body of the wearer when
the absorbent
article 20 is in use, the area of contact between the topsheet 24 of the
topsheet/acquisition layer
laminate 245 and the wearer's skin can be reduced in order to lead to an
enhanced dryness
feeling and comfort. Hence, the topsheet/acquisition layer laminate 245
provides cushioning to
the wearer and an improved sensation of comfort.
Fig. 19A-Fig. 19E shows alternatives how a plurality of three-dimensional
protrusions
250, e.g. bulbous-shaped protrusions, may protrude from the acquisition layer
52 to the topsheet
24 of the topsheet/acquisition layer laminate 245. In those alternatives, a
three-dimensional
protrusion 250 may comprise an inner and outer three-dimensional protrusion
251A and 251B.
The inner three-dimensional protrusion 251A of the acquisition layer 52 is
nested in the outer
three-dimensional protrusion 251B of the topsheet 24. The inner three-
dimensional protrusion
251A may comprise a plurality of looped fibers 254B of the acquisition layer
52. The outer three-
dimensional protrusion 251B in which the inner three-dimensional protrusion
251A is nested,
may comprise a plurality of looped fibers 254A of the topsheet 24.
An area of 10 cm2 of the topsheet/acquisition layer laminate 245 may comprise
from 5 to
100 three-dimensional protrusions 250 from 10 to 50 three-dimensional
protrusions 250 or from
20 to 40 three-dimensional protrusions 250.
Fiber concentration
The topsheet web 240 may comprise a generally planar first region of the
topsheet web
240. The acquisition layer 52 may comprise a generally planar first region of
the acquisition layer
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
39
52. The three-dimensional protrusions of the respective topsheet web 240 and
the acquisition
layer 52 may comprise a plurality of discrete integral second regions. The
term "generally
planar" is not meant to imply any particular flatness, smoothness, or
dimensionality. Thus, the
first region of the topsheet web 240 can include other features that provide
the first region of the
topsheet web 240 with a topography. The first region of the acquisition layer
52 can include other
features that provide the first region of the acquisition layer 52 with a
topography. Such other
features can include, but are not limited to small protrusions, raised network
regions around the
base 256 forming an opening, and other types of features. Thus, the first
region of the topsheet
web 240 and/or the first region of the acquisition layer 52 can be generally
planar when
considered relative to the respective second regions. The first region of the
topsheet web 240
and/or the first region of the acquisition layer 52 can have any suitable plan
view configuration.
In some cases, the first region of the topsheet web 240 and/or the first
region of the acquisition
layer 52 can be in the form of a continuous inter-connected network which
comprises portions
that surround each of the three-dimensional protrusions 250.
The side walls 259 and the area around the base 256 of the majority of the
three-
dimensional protrusions 250 may have a visibly significantly lower
concentration of fibers per
given area (which may be evidence of a lower basis weight or lower opacity)
than the portions of
the topsheet web 240 and/or the acquisition layer 52 in the unformed first
region of the respective
topsheet web 240 and the acquisition layer 52. The majority of the three-
dimensional protrusions
250 may also have thinned fibers in the side walls 259. Thus, the fibers may
have a first cross-
sectional area when they are in the undeformed topsheet web 240 and the
acquisition layer 52,
and a second cross-sectional area in the side walls 259 of the majority of the
three-dimensional
protrusions 250 of the topsheet/acquisition layer laminate 245, wherein the
first cross-sectional
area is greater than the second cross-sectional area. The side walls 259 may
also comprise some
broken fibers as well. The side walls 259 may comprise greater than or equal
to about 30%,
alternatively greater than or equal to about 50% broken fibers.
As used herein, the term "fiber concentration" has a similar meaning as basis
weight, but
fiber concentration refers to the number of fibers/given area, rather than
g/area as in basis weight.
The topsheet/acquisition layer laminate web 2450 may comprise the majority of
the three-
dimensional protrusions 250 which are oriented with the base 256 facing upward
in which the
concentration of fibers at the distal end 259 of each respective topsheet web
240 and the
acquisition layer 52 differs between the topsheet web 240 and the acquisition
layer 52.
The concentration of fibers in the first region of the acquisition layer 52
and in the distal
ends 259 of the majority of the three dimensional protrusions 250 may be
greater than the
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
concentration of fibers in the side walls 255 of the majority of the three
dimensional protrusions
250 in the acquisition layer 52
The concentration of fibers in the first region of the topsheet web 240 and in
the distal
ends 259 of the majority of the three dimensional protrusions 250 may be
greater than the
5 concentration of fibers in the side walls 255 of the majority of the
three dimensional protrusions
250 in the topsheet web 240.
Alternatively, the concentration of fibers in the first region of the
acquisition layer 52
may be greater than the concentration of fibers in the side walls 255 of the
majority of the three-
dimensional protrusions 250 in the acquisition layer 52, and the concentration
of fibers in the side
10 walls 255 of the majority of the three-dimensional protrusions 250 in
the acquisition layer 52
may be greater than the concentration of fibers forming the distal ends 259 of
the majority of the
three-dimensional protrusions 250 in the acquisition layer 52.
The concentration of fibers in the first region of the acquisition layer 52
may be greater
than the concentration of fibers in the distal ends 259 of the majority of the
three dimensional
15 protrusions 250 in the acquisition layer 52, and the concentration of
fibers in the first region of
the topsheet web 240 and the distal ends 259 of the majority of the three
dimensional protrusions
250 may be greater than the concentration of fibers in the side walls 255 of
the majority of the
three dimensional protrusions 250 in the topsheet web 240.
A portion of the fibers that form the first region fibers in the acquisition
layer 52 and/or
20 the topsheet web 240 may comprise thermal point bonds, and the portion
of the fibers in the
acquisition layer 52 and/or the topsheet web 240 forming the side walls 255
and distal ends 259
of the majority of the three-dimensional protrusions 250 may be substantially
free of thermal
point bonds. In at least some of the three-dimensional protrusions, at least
some of the fibers in
the acquisition layer 52 and/or the topsheet web 240 may form a nest or circle
around the
25 perimeter of the three-dimensional protrusion 250 at the transition
between the side wall 255 and
the base 256 of the three-dimensional protrusion 250.
In some cases, the topsheet web 240 or the acquisition layer 52 may have a
plurality of
bonds (such as thermal point bonds) therein to hold the fibers together. Any
such bonds are
typically present in the precursor materials from which the respective
topsheet web 240 or the
30 acquisition layer 52 are formed.
Forming three-dimensional protrusions 250 in the topsheet/acquisition layer
laminate web
2450 may also affect the bonds (thermal point bonds) within the topsheet web
240 and/or the
acquisition layer 52.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
41
The bonds within the distal end 259 of the three-dimensional protrusions 250
may remain
intact (not be disrupted) by the mechanical deformation process that formed
the three-
dimensional protrusions 250. In the side walls 255 of the three-dimensional
protrusions 250,
however, the bonds originally present in the precursor topsheet web 240 and/or
the acquisition
layer 52 may be disrupted. When it is said that the bonds may be disrupted,
this can take several
forms. The bonds can be broken and leave remnants of a bond. In other cases,
such as where the
precursor materials of the respective topsheet web 240 or the acquisition
layer 52 is
underbonded, the fibers can disentangle from a lightly formed bond site
(similar to untying a
bow), and the bond site will essentially disappear. In some cases, after the
mechanical
deformation process, the side walls 255 of the majority of the three-
dimensional protrusions 250
may be substantially free (or completely free) of thermal point bonds.
The bonds within the first region of the topsheet web 240 and the distal end
259 of the
three-dimensional protrusions 250 may remain intact. In the side walls 255 of
the three-
dimensional protrusions 250, however, the bonds originally present in the
precursor topsheet web
240 may be disrupted such that the side walls 255 are substantially free of
thermal point bonds.
Such a topsheet web 240 could be combined with an acquisition layer 52 in
which the
concentration of fibers within the topsheet web 240 in the first region and
the distal end 259 of
the three-dimensional protrusions 250 is also greater than the concentration
of fibers in the side
walls 255 of the three-dimensional protrusions 250.
The acquisition layer 52 may have thermal point bonds within the first region
of the
acquisition layer 52 and the distal end 259 of the three-dimensional
protrusions 250 that remain
intact. In the side walls 255 of the three-dimensional protrusions 250,
however, the bonds
originally present in the precursor acquisition layer 52 comprising the
acquisition layer 52 may
be disrupted such that the side walls 255 of the acquisition layer 52 are
substantially free of
thermal point bonds. In other cases, the thermal point bonds in the
acquisition layer 52 at the
distal end 259 of the three-dimensional protrusions 250 may also be disrupted
so that the distal
end 259 of at least some of the three-dimensional protrusions 250 are
substantially or completely
free of thermal point bonds.
Indicia
The topsheet web 240, the acquisition layer 52, and/or the carrier layer web
170 may
comprise one or more indicia. In other instances, more than one of these
layers or webs may
comprise an indicia.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
42
The term "indicia", as used herein, may comprise one or more inks with
pigments,
adhesives with pigments, words, designs, trademarks, graphics, patterns,
and/or pigmented areas,
for example. The term "indicia" does not include a fully tinted or colored
layer. The indicia may
typically be a different color than: (1) the layer or web that it is printed
on, positioned on, or
applied to; or (2) a different color than other layers or webs of an absorbent
article 20.
The phrase a "different color" means a different shade of the same color
(e.g., dark blue
and light blue) or may be completely different color (e.g., blue and gray).
The indicia should be at least partially visible from either a wearer facing
surface, a
garment facing surface, or both of an absorbent article 20, although the
indicia may not be
printed on, positioned or, on applied to the wearer or garment facing surfaces
of the absorbent
articles 20.
The indicia may be printed on, positioned on, or applied to three-dimensional
protrusions
areas and non three-dimensional protrusions areas, three-dimensional
protrusion areas only, or
non three-dimensional protrusions areas only, for example. A three-dimensional
protrusion area
may comprise a portion or all of the majority of the three-dimensional
protrusions 250.
The indicia may comprise a light activatable material, a liquid activatable
material, a pH
activatable material, a temperature activatable material, a menses activatable
material, a urine
activatable material, or BM activatable material, or an otherwise activatable
material. These
activatable materials may typically undergo a chemical reaction, or other
reaction, to change the
indicia from one color to a different color, from one color to a different
shade of the same color,
from a color that is not visually distinguishable in an absorbent article 20
to a color that is
visually distinguishable in an absorbent article 20, or from a color that is
visually distinguishable
in an absorbent article 20 to a color that is not visually distinguishable in
an absorbent article 20.
In an instance, the indicia may grow or shrink or display a graphic/not
display a graphic
after the indicia undergoes the reaction. In other instances, the indicia may
be activated by a
stress or a strain during manufacture or wear.
The indicia may be white or non-white. If the indicia is white in color, at
least one layer
may be non-white so that the indicia is visible from a wearer and/or garment
facing surface of the
absorbent articles 20, for example.
The indicia may comprise embossments, fusion bonds, or other mechanical
deformations.
In other instances the indicia may at least partially overlap embossments,
fusion bonds, or other
mechanical deformations.
In some instances, the indicia may be formed within either a sheath or a core
of
bicomponent fibers. For example, a core may be white, while a sheath may be
blue, or vice versa.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
43
The indicia may be on, positioned on, formed on, formed with, printed on, or
applied to
all of, or part of, a certain layer or web. The indicia may also be on,
positioned on, formed on,
formed with, printed on, or applied to one or more layers or webs, or on all
suitable layers or
webs of an absorbent article 20. The indicia may be on, positioned on, formed
on, formed with,
printed on, or applied to either side, or both sides, of the one or more
layers or webs of an
absorbent article 20. In some instances, suitable layers or webs for indicia
placement comprise
one or more of a topsheet web 240 or topsheet 24, a secondary topsheet, an
acquisition layer 52,
a distribution layer 54, a carrier layer web 170 or carrier layer 17, a core
wrap 160, a bottom side
16' of the core wrap 160, a top side 16 of the core wrap 160, and/or an
additional layer
positioned at least partially intermediate the topsheet 24 and the top side 16
of the core wrap 160
(hereafter sometimes referred to as "materials suitable for indicia
placement").
Either in addition to or separate from the indicia described above, any one or
more of the
suitable layers or webs for indicia placement, or a portion thereof, may have
a color different
than any one or more of the remaining layers or webs for indicia placement, or
a portion thereof.
The definition of the phrase "different color" above also applies to this part
of the disclosure. In
some instances, the indicia may be a different color than any one or more of
the suitable layers or
webs for indicia placement.
Alternatively, an indicia may be on one of the suitable layers or webs for
indicia
placement while another one of the remaining suitable layers or webs for
indicia placement may
be a different color than the indicia. One example may be a blue indicia on a
white carrier layer
web 170 with the acquisition layer 52 or topsheet web 240 being teal.
In another example, a blue indicia may be on a white carrier layer web 170
with the
acquisition layer 52 and topsheet web 240 also being white. As such, the blue
indicia may be
viewable from a wearer-facing surface.
In another example, a blue indicia may be on an acquisition layer 52, wherein
the
topsheet web 240 and the acquisition layer 52 are simultaneously mechanically
deformed and
combined together, preferably nested together to provide a
topsheet/acquisition layer laminate
web 2450 having three-dimensional protrusions 250.
In an instance where the topsheet and the acquisition layer are simultaneously
mechanically deformed and combined together, preferably nested together to
provide a
topsheet/acquisition layer laminate web 2450 having three-dimensional
protrusions 250, the
indicia may be applied to the acquisition layer 52 or the topsheet web 240
before or after such
mechanical deformation (or preferably namely nesting).
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
44
In an example, two different indicia may be positioned on the same or
different layers or
webs for indicia placement. The two different indicia may be different in
color, pattern, and/or
graphic, for example. If the two different indicia are on different layers or
webs for indicia
placement, the two layers may be the same color or different colors, or have
portions that are the
same color or different colors.
In some instances, a visible color of a portion of, or all of, the interior
(wearer-facing
surface) of an absorbent article 20 may be coordinated with and/or compliment
a visible color of
a portion of, or all of, the exterior (garment-facing surface) of the
absorbent article 20, as
described in further detail in U.S. Patent No. 8,936,584. The indicia visible
from the interior may
also be coordinated with and/or compliment the indicia visible from the
exterior of the absorbent
article 20. In such an instance, the backsheet 25 of the absorbent article 20
may comprise an
outer cover nonwoven and a backsheet film. The indicia visible from the
exterior of the absorbent
article 20 may be on the outer cover nonwoven or the backsheet film.
In still other instances, the visible indicia and/or color from the interior
may also be
coordinated with or compliment the indicia and/or color visible from the
exterior of the absorbent
article 20.
In addition to that described above, a first portion of one of the suitable
layers or webs for
indicia placement may be a first color and a second portion of the same of the
suitable layers or
webs for indicia placement may be a second color. The first and second colors
may be a different
color. In other instances, a first portion of one of the suitable layers or
webs for indicia placement
may be a first color and a second portion of a different one of the suitable
layers or webs for
indicia placement may be a second color. The first and second colors may be a
different color.
In an instance, in an absorbent article 20, one of a topsheet 24, an
acquisition layer 52, a
portion of a core wrap 160, or an additional layer (e.g., a carrier layer 170)
may be a different
color than a different one of the topsheet 24, the acquisition layer 52, the
portion of the core wrap
160, or the additional layer.
In another instance, in an absorbent article 20, one of a portion of a
topsheet 24, a portion
of an acquisition layer 52, a portion of a core wrap 160, or a portion of an
additional layer may be
a different color than a different one of the portion of the topsheet 24, the
portion of the
acquisition layer 52, the portion of the core wrap 160, or the portion of the
additional layer.
In another instance, in an absorbent article 20, a first portion of one of a
topsheet 24, an
acquisition layer 52, a portion of a core wrap 160, or an additional layer may
be a different color
as a second portion of the same one of the topsheet 24, the acquisition layer
52, the core wrap
160, or the additional layer.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
The process of the present disclosure may comprise applying the indicia to or
positioning
or printing the indicia on the topsheet web 240, the acquisition layer 52, the
carrier layer web
170, a portion of the core wrap 160, and/or an additional layer positioned at
least partially
intermediate the topsheet web 240 and the backsheet web 2555. The indicia may
be positioned or
5
printed on or applied to either side of the topsheet web 240, the acquisition
layer 52, the carrier
layer web 170, the portion of the core wrap 160, and/or the additional layer
positioned at least
partially intermediate the topsheet web 240 and the backsheet web 2555. If the
indicia is applied
to or positioned or printed on the topsheet web 240 or the acquisition layer
52, this step may be
done before or after the topsheet web 240 and the acquisition layer 52 are
simultaneously
10
mechanically deformed and combined together to provide the
topsheet/acquisition layer laminate
web 2450.
In some forms, the indicia may be positioned or printed on or applied to a
carrier layer
web 170 that comprises pulp fibers. In other forms, the indicia may be
positioned or printed on or
applied to a garment-facing surface or a wearer-facing surface of the
acquisition layer 52. In
15 some
instances, the materials suitable for indicia placement may be purchased with
indicia
thereon or the indicia may be applied to or printed or positioned on before or
during feeding
these materials into an absorbent article manufacturing line.
Precursor Materials for the topsheet and the acquisition layer
20 The
topsheet/acquisition layer laminate 245 of the present invention can be made
of any
suitable nonwoven materials ("precursor materials"). In some cases, the
topsheet/acquisition
layer laminate 245 may also be free of cellulose materials. The precursor
materials for the
topsheet/acquisition layer laminate 245 may have suitable properties in order
to be deformed.
The suitable properties of the precursor materials may include: apparent
elongation of the fibers,
25
fiber mobility, ability to deform and stretch in the area where the three-
dimensional protrusions
250 of the topsheet/acquisition layer laminate 245 are formed. Hence, the
precursor materials are
capable of undergoing mechanical deformation to ensure that the three-
dimensional protrusion
250 will not tend to recover or return to the prior configuration of a flat
topsheet 24 laminated on
a flat acquisition layer 52.
30
Several examples of nonwoven materials suitable for use as a topsheet 24 for
the
topsheet/acquisition layer laminate 245 may include, but are not limited to:
spunbonded
nonwovens; carded nonwovens; and nonwovens with relatively specific properties
to be able to
be readily deformed.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
46
One suitable nonwoven material as a topsheet 24 for the topsheet/acquisition
layer
laminate 245 may be an extensible polypropylene/polyethylene spunbonded
nonwoven. One
suitable nonwoven material as a topsheet 24 for the topsheet/acquisition layer
laminate 245 may
be a spunbonded nonwoven comprising polypropylene and polyethylene. The fibers
may
comprise a blend of polypropylene and polyethylene. Alternatively, the fibers
may comprise bi-
component fibers, such as a sheath-core fiber with polyethylene on the sheath
and polypropylene
in the core of the fiber.
The topsheet 24 of the topsheet/acquisition layer laminate 245 may have a
basis weight
from 8 to 40 gsm or from 8 to 30 gsm or from 8 to 20 gsm.
Suitable nonwoven materials for the acquisition layer 52 of the
topsheet/acquisition layer
laminate 245 may include, but are not limited to: spunbonded nonwovens,
through-air bonded
("TAB") carded high loft nonwoven materials, spunlace nonwovens,
hydroentangled nonwovens,
and resin bonded carded nonwoven materials. Spunbonded PET may be denser than
carded
nonwovens, providing more uniformity and opacity. Since PET fibers are not
very extensible, the
nonwoven can be bonded such that at least some of the fibers can be separated
easily from the
bond sites to allow the fibers to pull out of the bond sites and rearrange
when the material is
strained. This type of bonding, e.g. pressure bonding can help increasing the
level of mobility of
the fibers. Indeed, the fibers tend to pull out from the bond sites under
tension.
The acquisition layer exhibits a basis weight from 10 to 120 gsm or from 10 to
100 gsm
or from 10 to 80 gsm.
The topsheet 24 and/or acquisition layer 52 may have a density from 0.01 to
0.4 g/cm3 or
from 0.01 to 0.25 g/cm3 or from 0.04 to 0.15 g/cm3.
The topsheet 24 and acquisition layer 52 may be joined together prior or
during the
mechanical deformation. If desired an adhesive, chemical bonding, resin or
powder bonding, or
thermal bonding between the topsheet 24 and acquisition layer 52 may be
selectively utilized to
bond certain regions or all of the topsheet 24 and acquisition layer 52
together. In addition, the
topsheet 24 and acquisition layer 52 may be bonded during processing, for
example, by carding
the topsheet 24 of onto the acquisition layer 52 and thermal point bonding the
combined layers.
Prior to any mechanical deformation, the topsheet 24 may be attached to the
acquisition
layer 52. For instance, the topsheet 24 may be attached to the acquisition
layer 52 where the
topsheet 24 and the acquisition layer 52 overlaps. The attachment of the
topsheet 24 to the
acquisition layer 52 may include a uniform continuous layer of adhesive, a
discontinuous
patterned application of adhesive or an array of separate lines, spirals, or
spots of adhesive. The
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
47
basis weight of the adhesive in the topsheet/acquisition layer laminate 245
may be from 0.5 to 30
gsm or from 1 to 10 gsm or from 2 to 5 gsm.
Example
The topsheet and the acquisition layer were attached to each other with a hot
melt
adhesive applied in form of spirals with a basis weight of 5 gsm. The
acquisition layer was
centered onto the topsheet with respect to the topsheet and placed 50 mm from
the front MD
edge of the topsheet. The topsheet and acquisition layer attached together
form a composite web.
The topsheet and acquisition layer attached together have been simultaneously
mechanically deformed by passing them between a pair of intermeshing male and
female rolls.
The topsheet of the topsheet/acquisition layer laminate was in contact with
the male roll. The
acquisition layer of the topsheet/acquisition layer laminate was in contact
with the female roll.
The teeth on the male roll have a rounded diamond shape like that shown in
Fig. 14A, with
vertical sidewalls and a radiused or rounded edge at the transition between
the top and the
sidewalls of the tooth. The teeth are 0.186 inch (4.72 mm) long and 0.125 inch
(3.18 mm) wide
with a CD spacing of 0.150 inch (3.81 mm) and an MD spacing of 0.346 inch
(8.79 mm). The
recesses in the mating female roll also have a rounded diamond shape, similar
to that of the male
roll, with a clearance between the rolls of 0.032-0.063 inch (0.813-1.6 mm).
The process speed
was 800 fpm and the depth of engagement (DOE) was 0.155 inch (3.94 mm), with
the topsheet
being in contact with the male roll and the acquisition layer being in contact
with the female roll.
The topsheet of the topsheet/acquisition layer laminate was a hydrophilic
coated mono
component high elongation spunbond polypropylene (HES PP) nonwoven material
with a density
of 0.11 g/cm3. The mono component HES PP nonwoven material for the topsheet
has an overall
basis weight of 20 gsm. The mono component HES PP nonwoven material was first
coated with
a finish made of a fatty acid polyethylene glycol ester for the production of
a permanent
hydrophilic mono component HES PP nonwoven material. The topsheet of the
topsheet/acquisition layer laminate had a width of 168 mm and a length of 488
mm.
The acquisition layer of the topsheet/acquisition layer laminate was a
spunbond
nonwoven with a basis weight of 60 gsm with a density of 0.13 g/cm3. The
acquisition layer
comprises 7 denier PET/coPET (polyethylene terephthalate) trilobal bicomponent
fibers with a
70/30 ratio of PET/coPET which has been treated with a surfactant. The
acquisition layer of the
topsheet/acquisition layer laminate had a width of 90 mm and a length of 338
mm.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
48
Prototype Diapers for the Example
Diaper prototypes for the above example were produced using Pampers Active Fit
S4
(size 4) diaper commercially available in Germany in Nov 2014. Pampers Active
Fit S4 (size 4)
diaper comprises a topsheet, an acquisition layer beneath the topsheet, a
distribution layer
beneath the acquisition layer, an absorbent core between the distribution and
a backsheet beneath
the absorbent core. Diaper prototypes for the above example were produced
using Pampers
Active Fit S4 (size 4) diaper.
The topsheet and acquisition layer attached together for the above example
were placed
on top of a Pampers Active Fit diaper commercially available in Germany in Nov
2014 from
where the commercial topsheet and acquisition layer were removed while keeping
the
distribution layer in place. For each diaper prototype based on the above
example, the
topsheet/acquisition layer laminate were placed on top of the distribution
layer with the three-
dimensional protrusions protruding towards the backsheet.
The acquisition layer front edge is placed 10 mm from the distribution layer
front edge.
The topsheet/acquisition layer laminate was attached onto the distribution
layer and the absorbent
core with a hot melt adhesive applied all over the side of the
topsheet/acquisition layer laminate
facing the distribution layer. The hot melt adhesive was applied in form of
spirals with a basis
weight of 5 gsm.
The three-dimensional protrusions of the topsheet/acquisition layer laminate
were
protruding towards the backsheet because the topsheet of the
topsheet/acquisition layer laminate
was in contact with the male roll, as set out above.
Each prototype diaper was compacted in a bag at an In Bag Stack Height, i.e.
the total
caliper of 10 bi-folded diapers, of 90 mm for 1 week. Then the bag was opened
and the diapers
out of the bag were conditioned at least 24 hours prior to any testing at 23
C +/- 2 C and 50%
+/- 10% Relative Humidity (RH).
The measured protrusion height and the measured protrusion base width of the
three-
dimensional protrusions of the topsheet/acquisition layer laminate have been
measured according
to the respective Protrusions Height and Protrusion Base Width Test Methods
(Table 1).
Table 1 Average measurements of the height and width of the protrusions
Example
Standard
average deviation
Measured Protrusion Base Width, mm 2,60 0,20
Measured Protrusion Height, mm 1.30 0,20
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
49
Test Methods
Wet Burst Test Method
The Wet Burst Strength as used herein is a measure of the ability of a fibrous
structure to
absorb energy, when wet and subjected to deformation with regard to the plane
of the fibrous
structure.
The wet burst strength of a fibrous structure (referred to as "sample" within
this test
method) is determined using an electronic burst tester and specified test
conditions. The results
obtained are averaged out of 4 experiments and the wet burst strength is
reported for a fibrous
structure 55 consisting of one single layer of wet-laid fibers.
Equipment
- Apparatus: Burst Tester ¨ Thwing-Albert Vantage Burst Tester or
equivalent ball burst
instrument where the ball moves downward during testing. Refer to
manufacturer's operation and
set-up instructions. The ball diameter is 1.59 cm and the clamp opening
diameter is 8.9 cm.
- Calibration Weights - Refer to manufacturer's Calibration instructions
- Conditioned Room Temperature and Humidity controlled within the following
limits for
Laboratory testing:
Temperature: 23 1 C
Relative humidity: 50% 2 %
- Paper Cutter - Cutting board, 600 mm size
- Scissors - 100 mm, or larger
- Pan - Approximate Width/Length/Depth: 240 x 300 x 50 mm, or equivalent
- Distilled water at the temperature of the conditioned room used
Sample Preparation
The fibrous structure 55 may be unwound from the roll.
The samples to be tested are conditioned in the conditioned room for 24 hours
immediately
before testing. All testing occurs within the conditioned room.
Cut the samples so that they are approximately 228 mm in length and width of
approximately
140 mm in width.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
Operation
Set-up and calibrate the Burst Tester instrument according to the
manufacturer's instructions for
the instrument being used.
Holding the sample by the narrow edges, the center of the sample is dipped
into a pan filled
5 approximately 25 mm from the top with distilled water. The sample is left
in the water for 4 (
0.5) seconds.
The excess water is drained from the sample for 3 ( 0.5) seconds holding the
sample in a
vertical position.
The test should proceed immediately after the drain step. The sample should
have no
10 perforations, tears or imperfections in the area of the sample to be
tested. If it does, start the test
over.
The sample is placed between the upper and lower rings of the Burst Tester
instrument. The
sample is positioned centered and flat on the lower ring of the sample holding
device in a manner
such that no slack in the sample is present.
15 The upper ring of the pneumatic holding device is lowered to secure the
sample.
The test is started. The test is over at sample failure (rupture) i.e., when
the load falls 20g from
the peak force. The maximum force value is recorded.
The plunger will automatically reverse and return to its original starting
position.
20 The upper ring is raised in order to remove and discard the tested
sample.
The procedure is repeated until all replicates have been tested.
Calculation
Wet Burst Strength = sum of peak load readings / number of replicates tested
25 Report the Wet Burst results to the nearest gram.
Accelerated Compression Method
1. Cut 10 samples of the topsheet/acquisition layer laminate 245 (called
herein specimen) to
be tested and 11 samples of paper towel into a 3 inch x 3 inch (7.6 cm x 7.6
cm) square.
30 2. Measure the caliper of each of the 10 specimens at 2.1 kPa and a
dwell time of 2 seconds
using a Thwing-Albert ProGage Thickness Tester or equivalent with a 50-60
millimeter
diameter circular foot. Record the pre-compression caliper to the nearest 0.01
mm.
3. Alternate the layers of the specimens to be tested with the paper towels,
starting and
ending with the paper towels. The choice of paper towel does not matter and is
present to
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
51
prevent "nesting" of the protrusions in the deformed samples. The samples
should be
oriented so the edges of each of the specimens and each of the paper towels
are relatively
aligned, and the protrusions in the specimens are all oriented the same
direction.
4. Place the stack of samples into a 40 C oven and place a weight on top of
the stack. The
weight must be larger than the foot of the thickness tester. To simulate high
pressures or
low in-bag stack heights, apply 35 kPa (e.g. 17.5 kg weight over a 70x70 mm
area). To
simulate low pressures or high in-bag stack heights, apply 7 kPa (e.g. 3.5 kg
weight over
a 70x70 mm area).
5. Leave the samples in the oven for 15 hours. After the time period has
elapsed, remove the
weight from the samples and remove the samples from the oven.
6. Within 30 minutes of removing the samples from the oven, measure the post-
compression
caliper as directed in step 2 above, making sure to maintain the same order in
which the
pre-compression caliper was recorded. Record the post-compression caliper of
each of the
10 specimens to the nearest 0.01 mm.
7. Let the samples rest at 23 2 C and at 50 2% relative humidity for 24
hours without
any weight on them.
8. After 24 hours, measure the post-recovery caliper of each of the 10
specimens as directed
in step 2 above, making sure to maintain the same order in which the pre-
compression
and post-compression calipers were recorded. Record the post-recovery caliper
of each of
the 10 specimens to the nearest 0.01 mm. Calculate the amount of caliper
recovery by
subtracting the post-compression caliper from the post-recovery caliper and
record to the
nearest 0.01 mm.
9. If desired, an average of the 10 specimens can be calculated for the pre-
compression,
post-compression and post-recovery calipers.
Protrusion Base Width and Protrusion Hei2ht Test Methods
1) General information
The Measured Protrusion Base Width and Measured Protrusion Height of the three-
dimensional protrusions of the topsheet/acquisition layer laminate of an
absorbent article are
measured using a GFM Primos Optical Profiler instrument commercially available
from
GFMesstechnik GmbH, WarthestraBe 21, D14513 Teltow/Berlin, Germany.
Alternative suitable
non-touching surface topology profilers having similar principles of
measurement and analysis,
can also be used, here GFM Primos is exemplified.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
52
The GFM Primos Optical Profiler instrument includes a compact optical
measuring
sensor based on a digital micro mirror projection, consisting of the following
main components:
a) DMD projector with 800 x 600 direct digital controlled micro-minors
b) CCD camera with high resolution (640 x 480 pixels)
c) Projection optics adapted to a measuring area of at least 30 x 40 mm
d) Recording optics adapted to a measuring area of at least 30 x 40 mm
e) A table tripod based on a small hard stone plate
0 A cold light source (an appropriate unit is the KL 1500 LCD, Schott North
America, Inc.,
Southbridge, MA)
g) A measuring, control, and evaluation computer running ODSCAD 6.3 software
Turn on the cold-light source. The settings on the cold-light source are set
to provide a
color temperature of at least 2800K.
Turn on the computer, monitor, and open the image acquisition/analysis
software. In the
Primos Optical Profiler instrument, select "Start Measurement" icon from the
ODSCAD 6.3 task
bar and then click the "Live Image button".
The instrument is calibrated according to manufacturer's specifications using
calibration
plates for lateral (X-Y) and vertical (Z). Such Calibration is performed using
a rigid solid plate of
any non-shiny material having a length of 11 cm, a width of 8 cm and a height
of 1 cm. This
plate has a groove or machined channel having a rectangular cross-section, a
length of 11 cm, a
width of 6.000 mm and an exact depth of 2.940 mm. This groove is parallel to
the plate length
direction. After calibration, the instrument must be able to measure the width
and depth
dimensions of the groove to within 0.004 mm.
All testing is performed in a conditioned room maintained at 23 2 C and 50+1-
10%
relative humidity. The surface to be measured may be lightly sprayed with a
very fine white
powder spray. Preferably, the spray is NORD-TEST Developer U 89, available
from Helling
GmbH, Heidgraben, Germany.
2) Protrusion Base Width Test Method
The topsheet/acquisition layer laminate is extracted from the absorbent
article by
attaching the absorbent article to a flat surface in a taut planar (i.e.
stretched planar) configuration
with the topsheet of the topsheet/acquisition layer laminate facing up. Any
leg or cuff elastics are
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
53
severed in order to allow the absorbent article to lie flat. Using scissors,
two longitudinal cuts are
made through all layers above the absorbent core (i.e. the core wrap) along
the edges of the
topsheet/acquisition layer laminate. Two transversal cuts are made through the
same layers
following the front and back waist edges of the absorbent article.
The topsheet/acquisition layer laminate and any other layers above the
absorbent core are
then removed without perturbing the topsheet/acquisition layer laminate.
Freeze spray (e.g. CRC
Freeze Spray manufactured by CRC Industries, Inc. 885 Louis Drive, Warminster,
PA 18974,
USA), or equivalent aid may be used to facilitate removal of the uppermost
layers from the
absorbent article. The topsheet/acquisition layer laminate is then separated
from any other layers,
including any carrier layer (e.g. a nonwoven carrier layer, a tissue layer),
using freeze spray if
necessary. If a distribution layer, e.g. a pulp containing layer is attached
to the
topsheet/acquisition layer laminate, any residual cellulose fibers are
carefully removed with
tweezers without modifying the acquisition layer.
The topsheet/acquisition layer laminate with three-dimensional protrusions
(conditioned
at a temperature of 23 C 2 C and a relative humidity of 50% 10% for at
least 24 hours)
namely "the specimen" is laid down on a hard flat horizontal surface with the
body-facing side
upward, i.e. the topsheet of the topsheet/acquisition layer laminate being
upward. Ensure that the
specimen is lying in planar configuration, without being stretched, with the
specimen uncovered.
A nominal external pressure of 1.86 kPa (0.27 psi) is then applied to the
specimen. Such
nominal external pressure is applied without interfering with the topology
profile measurement.
Such an external pressure is applied using a transparent, non-shining flat
Plexiglas plate 200
mm by 70 mm and appropriate thickness (approximately 5 mm) to achieve a weight
of 83g. The
plate is gently placed on top of the specimen, such that the center point of
the Plexiglas plate is
at least 40 mm away from any folds, with the entire plate resting on the
specimen. A fold
corresponds to a part of the absorbent article (e.g. the topsheet/acquisition
layer laminate) where
the absorbent article has been folded for packaging purposes.
Two 50 mm x 70 mm metal weights each having a mass of 1200 g (approximate
thickness
of 43 mm) are gently placed on the Plexiglas plate such that a 70 mm edge of
each metal
weight is aligned with the 70 mm edges of the Plexiglas plate. A metal frame
having external
dimensions of 70 mm x 80 mm and interior dimensions of 42 mm x 61 mm, and a
total weight of
142g (approximate thickness 6 mm), is positioned in the center of the
Plexiglas plate between
the two end weights with the longest sides of the frame aligned with the
longest sides of the
plate.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
54
If the specimen is smaller than 70 x 200 mm, or if a large enough area without
a fold is
not present, or if an area of interest is close to the edges of the specimen
and can't be analyzed
with the Plexiglas and weights settings described above, then the X-Y
dimensions of the
Plexiglas plate and the added metal weights may be adjusted to reach a
nominal external
pressure of 1.86 kPa (0.27 psi) while maintaining a minimum 30 x 40 mm field
of view. At least
complete three-dimensional protrusions of the specimen should be captured in
the field of
view of 30 mm x 40 mm.
Position the projection head to be normal to the specimen surface (i.e. to the
topsheet of the
10 topsheet/acquisition layer laminate).
Adjust the distance between the specimen and the projection head for best
focus.
In the Primos Optical Profiler instrument, turn on the button "Pattern" to
make a red cross appear
on the screen ross and a black cross appears on the specimen.
Adjust the focus control until the black cross is aligned with the red cross
on the screen.
Adjust image brightness then capture a digitized image.
In the Primos Optical Profiler instrument, change the aperture on the lens
through the hole in the
side of the projector head and/or altering the camera "gain" setting on the
screen.
When the illumination is optimum, the red circle at the bottom of the screen
labeled "I.O." will
turn green.
Click on the "Measure" button.
The topology of the upper surface of the topsheet/acquisition layer laminate
specimen is
measured through the Plexiglas plate over the entire field of view 30 mm x 40
mm. It is
important to keep the specimen still stationary during this time in order to
avoid blurting of the
captured image. The image should be captured within the 30 seconds following
the placement of
the Plexiglas plate, metal weights and frame on top of the specimen.
After the image has been captured, the X-Y-Z coordinates of every pixel of the
40 mm x
mm field of view area are recorded. The X direction is the direction parallel
to the longest
edge of the rectangular field of view, the Y direction is the direction
parallel to the shortest edge
30 of the rectangular field of view. The Z direction is the direction
perpendicular to the X-Y plane.
The X-Y plane is horizontal while the Z direction is vertical, i.e. orthogonal
to the X-Y plane.
These data are smoothed and filtered using a polynomial filter (n = 6), a
median filter 11
pixels by 11 pixels, and a structure filter 81 pixels by 81 pixels. The
polynomial filter (n=6)
approximates the X-Y-Z coordinate surface with a polynomial of order 6 and
returns the
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
difference to the approximated polynomial. The median filter 11 pixels by 11
pixels divides the
field of view (40 mm x 30 mm) in X-Y squares of 11 pixels by 11 pixels. The Z
coordinate of the
pixel located at the center of a given 11 pixels by 11 pixels square will be
replaced by the mean Z
value of all the pixels of this given square. The structure filter 81 pixels
by 81 pixels, removes the
5 waviness of the structure and translates all the Z peak values belonging
to the bottom surface of
the Plexiglas plate to a top X-Y plane.
A Reference Plane is then defined as the X-Y plane intercepting the surface
topology
profile of the entire field of view (i.e. 30 mm x 40mm), 100 microns below
this top X-Y plane. In
the Primos Optical Profiler instrument, to measure the Material Area of the
Reference Plane (Z=-
10 0.1mm), click on the button "Evaluate". Then, apply a pre-filtering
routine including a
polynomial filter (n=6), a median filter 11 by 11 and a structure filter
(n=81) using the function
"Filter". Save the image to a computer file with ".omc" extension.
The same above procedure is then executed on the topsheet/acquisition layer
laminate
with the garment-facing side upward (i.e. the acquisition layer of the
topsheet/acquisition layer
15 laminate being upward), the 40 mm x 30 mm field of view being located at
the exact same X-Y
position of the topsheet/acquisition layer laminate.
The Empty Area of the reference plane can be defined as the area of the
Reference Plane
that is above the surface profile. The Empty Areas having boundaries strictly
located inside the
field of view area (i.e. 30 mm x 40 mm) without crossing or overlapping with
the boundaries of
20 the field of view area (i.e. 40 mm x 30 mm) are defined as Isolated
Empty Area(s). The
Measured Protrusion Base Width is defined for an Isolated Empty Area as the
diameter of the
biggest circle that can be inscribed inside a given Isolated Empty Area. This
circle should only
overlap with the Isolated Empty Area.
In the Primos Optical Profiler instrument, this can be done by clicking on
"Draw circle"
25 and drawing the biggest inscribed circle possible in a chosen Isolated
Empty Area. Click on
"Show sectional picture", the circle diameter can be measure via clicking on
the extremity of the
sectional picture profile and then clicking on "Horizontal distance" to obtain
the Protrusion Base
Width.
For both of the acquired and digitized images, the Protrusion Base Width of
all the
30 Isolated Empty Areas is determined. Then, the Measured Protrusion Base
Width is calculated as
the arithmetic average of the 6 biggest Protrusion Base Widths.
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
56
3) Protrusion Height Test Method
The topsheet/acquisition layer laminate is extracted from the absorbent
article as
described above in the Protrusion Base Width Test Method.
The topsheet/acquisition layer laminate specimen comprising three-dimensional
protrusions is then conditioned and scanned under a pressure of 1.86 kPa (0.27
psi) with the
body-facing side upward, i.e. the topsheet of the topsheet/acquisition layer
laminate being
upward as described above in the Protrusion Base Width Test Method.
After the image has been captured, the X-Y-Z coordinates of every pixel of the
40 mm x
30 mm field of view area are recorded and smoothed/filtered as described above
in the Protrusion
Base Width Test Method. A reference plane is also defined as described above
in the Protrusion
Base Width Test Method.
In the Primos Optical Profiler instrument, to measure the Material Area of the
Reference
Plane (Z=-0.1mm), click on the button "Evaluate". Then apply a pre-filtering
routine including a
polynomial filter (n=6), a median filter 11 by 11 and a structure filter
(n=81) using the function
"Filter". Save the image to a computer file with ".omc" extension.
The same above procedure set out in the Protrusion Base Width Test Method is
then
executed on the topsheet/acquisition layer laminate with the garment-facing
side upward (i.e. the
acquisition layer of the topsheet/acquisition layer laminate being upward),
the 40 mm x 30 mm
field of view being located at the exact same X-Y position of the
topsheet/acquisition layer
laminate.
The Empty Area of the reference plane can be defined as the area of the
Reference Plane
that is above the surface profile. The Empty Area having boundaries strictly
located inside the
field of view area (i.e. 30 mm x 40 mm) without crossing or overlapping with
the boundaries of
the field of view area (i.e. 40 mm x 30 mm) are defined as Isolated Empty
Area(s). The
Protrusion Height is defined for an Isolated Empty Area as the distance
between the minimum Z
value of the points of the topsheet/acquisition layer laminate surface profile
having X-Y
coordinates located in this Isolated Empty Area, and the Z value of the top X-
Y plane.
Click on "Draw N parallel lines" and draw a first segment parallel to the X
axis of the
field of view (direction of the longest dimension of the field of view)
passing through the center
of the Isolated Empty Area and extending outside the Isolated Empty Area
boundaries. The
center of the Isolated Empty Area corresponds to the middle of the segment
parallel to the Y axis
of the field of view and joining the biggest and smallest Y value of the
Isolated Empty Area.
Then input the "number" of lines to be drawn and set the "distance" between
lines to 0.05mm.
Enough lines need to be drawn such to cover the entire Isolated Empty Area.
Leave the averaging
CA 02960974 2017-03-10
WO 2016/040090 PCT/US2015/048302
57
parameter to 0 then click "Ok". Then click on "Show sectional picture". Click
on the point of the
sectional picture profile having the minimum Z value and click on "Vertical
distance" to obtain
the Protrusion Height.
For both of the acquired and digitized images, the Protrusion Height of all
the Isolated
Empty Areas is determined. Then, the Measured Protrusion Height is calculated
as the arithmetic
average of the 6 biggest Protrusion Heights.
The dimensions and values disclosed herein are not to be understood as being
strictly
limited to the exact numerical values recited. Instead, unless otherwise
specified, each such
dimension is intended to mean both the recited value and a functionally
equivalent range
surrounding that value. For example, a dimension disclosed as "40 mm" is
intended to mean
"about 40 mm."
Every document cited herein, including any cross referenced or related patent
or
application, is hereby incorporated herein by reference in its entirety unless
expressly excluded
or otherwise limited. The citation of any document is not an admission that it
is prior art with
respect to any invention disclosed or claimed herein or that it alone, or in
any combination with
any other reference or references, teaches, suggests or discloses any such
invention. Further, to
the extent that any meaning or definition of a term in this document conflicts
with any meaning
or definition of the same term in a document incorporated by reference, the
meaning or definition
assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated
and
described, it would be obvious to those skilled in the art that various other
changes and
modifications can be made without departing from the spirit and scope of the
invention. It is
therefore intended to cover in the appended claims all such changes and
modifications that are
within the scope of this invention.
