PROCESS FOR MAKING AN ABSORBENT ARTICLE COMPRISING A TOPSHEET/ACQUISITION LAYER LAMINATE

A process of making an absorbent article comprising the steps of 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 and an acquisition layer having a first and second surface. The topsheet web and the acquisition layer comprise fibers. The process comprises the step of aligning the topsheet web and the acquisition layer in a face to face relationship such that the second surface of the topsheet web in in contact with the first surface of the acquisition layer. The process comprises the step of 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.

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Description
RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. Nos. 62/049,516 (P&G 13530P), 62/049,521 (P&G 13531PQ), 62/049,408 (P&G CM4137FPQ), 62/049,406 (P&G CM4136FPQ), 62/049,404 (P&G CM4135FPQ), 62/049,403 (P&G CM4134FPQ), 62/049,401 (P&G CM4133FPQ), 62/049,397 (P&G CM4132FPQ), and 62/049,392 (P&G CM4131FPQ), all of which were filed on Sep. 12, 2014, and to U.S. Provisional Patent Application Ser. Nos. 62/210,005 (P&G 13971PQ), 62/210,014 (P&G 13972PQ), 62/210,020 (P&G 13973PQ), and 62/210,057 (P&G CM 4131P2Q), all of which were filed on Aug. 26, 2015. The entire disclosures of all of the above-referenced U.S. Provisional Patent Applications are fully incorporated herein by reference.

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 A1.

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 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 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.

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 20× 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.

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 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.

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;

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;

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:

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-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 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 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.

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.

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.

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.

“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.

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 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 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 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 barrier 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 barrier 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.

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 ⅓ 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 U.S. Pat. No. 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 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 U.S. Pat. No. 5,599,335 (Goldman), EP1447066A1 (Busam), WO95/11652 (Tanzer), US2008/0312622A1 (Hundorf), and WO2012/052172 (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 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 U.S. Pat. No. 7,744,576, US2011/0268932A1, US2011/0319848A1 or US2011/0250413A1. 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.

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 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 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 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.

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.

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 A1 (Hundorf).

Exemplary chemically cross-linked cellulosic fibers suitable for a distribution layer 54 are disclosed in U.S. Pat. No. 5,549,791; U.S. Pat. No. 5,137,537; WO95/34329 or US2007/118087. 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 (2.07 kPa).

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 B1, WO 97/31971 A1, WO 99/44648 A1 and WO 00/52087 A1.

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.

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.

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 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 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 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 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 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 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 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.

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 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 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. Pat. 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 A1, Orr, 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.

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 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.

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.

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 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 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 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%.

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.

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-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, 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 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 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 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.

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 20× 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.

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 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 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 FIG. 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 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 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 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 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 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 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 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 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 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.

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.

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.

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).

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. Pat. 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.

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 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 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 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

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, 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.

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.

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 bicomponent 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 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.

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 November 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 November 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

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: 240×300×50 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.

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 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 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.

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 20 g from the peak force. The maximum force value is recorded.

The plunger will automatically reverse and return to its original starting position.

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

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×3 inch (7.6 cm×7.6 cm) square.
    • 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 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 70×70 mm area). To simulate low pressures or high in-bag stack heights, apply 7 kPa (e.g. 3.5 kg weight over a 70×70 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 Height 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.

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 800×600 direct digital controlled micro-mirrors
    • b) CCD camera with high resolution (640×480 pixels)
    • c) Projection optics adapted to a measuring area of at least 30×40 mm
    • d) Recording optics adapted to a measuring area of at least 30×40 mm
    • e) A table tripod based on a small hard stone plate
    • f) A cold light source (an appropriate unit is the KL 1500 LCD, Schott North America, Inc., Southbridge, Mass.)
    • 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+/−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 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 83 g. 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×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×80 mm and interior dimensions of 42 mm×61 mm, and a total weight of 142 g (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.

If the specimen is smaller than 70×200 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 30×40 mm field of view. At least 10 complete three-dimensional protrusions of the specimen should be captured in the field of view of 30 mm×40 mm.

Position the projection head to be normal to the specimen surface (i.e. to the topsheet of the 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×40 mm. It is important to keep the specimen still stationary during this time in order to avoid blurring 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×30 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 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 difference to the approximated polynomial. The median filter 11 pixels by 11 pixels divides the field of view (40 mm×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 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×40 mm), 100 microns below this top X-Y plane. In the Primos Optical Profiler instrument, to measure the Material Area of the Reference Plane (Z=−0.1 mm), 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 laminate being upward), the 40 mm×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×40 mm) without crossing or overlapping with the boundaries of the field of view area (i.e. 40 mm×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” 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 Isolated Empty Areas is determined. Then, the Measured Protrusion Base Width is calculated as the arithmetic average of the 6 biggest Protrusion Base Widths.

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×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=−0.1 mm), 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×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×40 mm) without crossing or overlapping with the boundaries of the field of view area (i.e. 40 mm×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 0.05 mm. Enough lines need to be drawn such to cover the entire Isolated Empty Area. Leave the averaging 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.

Claims

1. A process of making an absorbent article comprising 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 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 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; 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.

2. The process of claim 1 comprising 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 wet-laid fibrous structure is positioned between the topsheet/acquisition layer laminate web and the backsheet web.

3. A process of making an absorbent article comprising 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 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 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 wherein the second surface of the carrier layer web is facing the topsheet/acquisition layer laminate web or the backsheet web.

4. The process of claim 3 comprising the step of cutting into individual absorbent articles comprising a backsheet, a topsheet and an acquisition layer, characterized in that the topsheet and the acquisition layer are joined to form a topsheet/acquisition layer laminate.

5. The process of claim 3 comprising the step of providing the acquisition layer is provided continuously or intermittently in the machine direction.

6. The process of claim 3 comprising the step of joining the portion of the backsheet web to the portion of the topsheet web at or adjacent to the transversal edges of the first surface of the topsheet/acquisition layer laminate web in the cross direction, wherein the transversal edges of the first surface of the topsheet/acquisition layer laminate web is free of any portion of the acquisition layer.

7. The process of claim 3 comprising providing the dry-laid fibrous structure which comprises a mixture of superabsorbent polymers and dry-laid fibers.

8. The process of claim 3 comprising the step of providing an absorbent core, wherein the absorbent core comprises an absorbent material.

9. The process of claim 8 wherein the carrier layer web is disposed between the topsheet/acquisition layer laminate web and the dry-laid fibrous structure or between the dry-laid fibrous structure and the absorbent core.

10. The process of claim 9 wherein the absorbent material comprises at least 80% of superabsorbent polymers, up to substantially 100% of superabsorbent polymers, by total weight of the absorbent material.

11. The process of claim 3, wherein step (c) comprises the following steps:

(1) providing a first and second forming member having a machine direction orientation and a cross direction orientation, said forming members comprising:
a first forming member having a surface comprising a plurality of discrete, spaced apart male forming elements having a base that is joined to the first forming member, a top that is spaced away from the base, and sides that extend between the base and the top of the male forming elements,
a second forming member having a surface defining a plurality of recesses in therein, wherein the recesses are aligned and configured to receive the respective male forming elements therein; and
(2) engaging the topsheet web and the acquisition layer together between the forming members and simultaneously mechanically deforming and combining the topsheet web together with the acquisition layer using the forming members to form a topsheet/acquisition layer laminate web, such that the topsheet/acquisition layer laminate web comprises deformations forming the three-dimensional protrusions.

12. The process of claim 3 wherein the majority of the three-dimensional protrusions have a shape selected from the group consisting of a bulbous shape, a conical shape, a mushroom shape and combinations thereof when the three-dimensional protrusions are viewed from a cross-sectional view in a Z-direction.

13. The process of claim 3 comprising the step of forming the topsheet/acquisition layer laminate web by nesting together the topsheet web and the 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.

14. The process of claim 3 comprising the step of forming the topsheet/acquisition layer laminate web by interrupting one of the topsheet web or the 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

15. The process of claim 3 comprising the step of forming the topsheet/acquisition layer laminate web by interrupting one of the topsheet web or the 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-dimensional protrusions of the interrupted topsheet web or acquisition layer.

16. The process of claim 3 comprising the step of forming the topsheet/acquisition layer laminate web by interrupting the topsheet web and the 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, and wherein the interruptions in the topsheet web in the area of the three-dimensional protrusions of the topsheet/acquisition layer laminate web does not coincide with the interruptions in the acquisition layer in the area of the three-dimensional protrusions of the topsheet/acquisition layer laminate web.

17. The process of claim 3 comprising the step of providing the carrier layer web which is colored.

18. The process of claim 3 comprising the step of providing the topsheet web, the acquisition layer, and/or the carrier layer web with an indicia thereon.

19. The process of claim 3 comprising the step of applying an indicia to the topsheet web, the acquisition layer, and/or the carrier layer web.

20. The process of claim 3 comprising the step of printing an indicia on the topsheet web, the acquisition layer, and/or the carrier layer web.

Patent History
Publication number: 20160074237
Type: Application
Filed: Sep 3, 2015
Publication Date: Mar 17, 2016
Inventors: Rodrigo ROSATI (Frankfurt Am Main), Jill Marlene ORR (Liberty Township, OH), Adrien GRENIER (Frankfurt Am Main), James T. KNAPMEYER (Cincinnati, OH), John B. STRUBE (Okeana, OH), Aniruddha CHATTERJEE (Kelkheim), Matthew S. RITTER (Liberty Township, OH)
Application Number: 14/844,292
Classifications
International Classification: A61F 13/15 (20060101); A61F 13/534 (20060101); A61F 13/53 (20060101); A61F 13/511 (20060101); A61F 13/513 (20060101);