ABSORBENT ARTICLE

专利摘要:
absorbent article. an absorbent article with improved handling of body exudates. the absorbent article can minimize the amount of body exudates in contact with the wearer's skin and can minimize the incidence of leakage of body exudates from the absorbent article.
公开号:BR112015009740B1
申请号:R112015009740-5
申请日:2013-10-30
公开日:2021-09-14
发明作者:Daniel Robert Schlinz；Eric Donald Johnson；Robert Lee Popp；David Glen Biggs；Niall Finn；Scott S.C. Kirby；Andy R. Butler；Andrew Thomas Hammond；Kendell Jean Williams
申请人:Kimberly-Clark Worldwide, Inc；
IPC主号:

专利说明:

HISTORY OF THE INVENTION
[1] The primary function of absorbent personal care articles is to absorb and retain body exudates such as urine, fecal matter, blood and menses, with additional desirable attributes including low leakage of absorbent article exudates and a dry feeling felt by the user of the absorbent article. To accomplish these tasks, absorbent personal care articles generally have an absorbent core and a cover surrounding the absorbent core. The cover is normally liquid permeable on the body-facing side of the absorbent core and fluid-impervious on the garment-facing side of the absorbent core. Absorbent articles usually fail, however, to prevent leakage of bodily secretions. Some bodily secretions, such as solid and semi-solid fecal material and menstruation, have difficulty penetrating the body-facing material of the absorbent article as easily as low-viscosity secretions, such as urine, and tend to spread across the entire surface of the body-facing material. body. Such spreading of bodily secretions can result in leakage of bodily secretions from the absorbent article.
[2] Semi-solid fecal material, such as a low-viscosity fecal material that may predominate with younger children, and menstruation may be especially difficult to contain in an absorbent article. Such secretions may move around the body facing material of an absorbent article under the influence of gravity, motion, and pressure by the user of the absorbent article. The migration of secretions is often towards the perimeter of the absorbent article, increasing the likelihood of leakage and spreading against the wearer's skin which can make skin cleaning difficult.
[3] Attempts have been made in the past to provide the body facing material for an absorbent article that can solve the problems described above. One such approach has been to use various types of embossing to create three-dimensionality in the body facing surface of the absorbent article. This approach, however, requires high basis weight material to create a structure with significant topography. Furthermore, it is inherent in the stamping process that the starting thickness of the material is lost due to the fact that stamping is, by its nature, a pressing and joining process. In addition, to "set" the embossments in a non-woven fabric, the densified section is typically fused to create weld spots that are normally impervious to the passage of bodily secretions. Therefore, a portion of the area for bodily secretions to transit through the material is lost. Also, "adjusting" the fabric can cause the material to stiffen and become rough to the touch.
[4] Another approach has been to form fibrous webs on three-dimensionally formed surfaces. The resulting structures typically have little resilience at low basis weights (whereas long fibers with desirable aesthetic attributes are used) and the topography is significantly degraded when wound onto a roll and passed through subsequent converting processes. This is partially addressed in the three-dimensional forming process by allowing the three-dimensional shape to be filled with fiber. This, however, usually comes at a higher cost due to the use of more material. This also results in a loss of smoothness and the resulting material becomes aesthetically unpleasant for certain applications.
[5] Another approach has been to have an opening in a fibrous web. Depending on the process, this can generate a flat two-dimensional weft or a weft with a three-dimensionality where the displaced fiber is pushed out of the plane of the original weft. Usually, the extent of three-dimensionality is limited and, under sufficient load, the displaced fiber can be pushed back towards its original position resulting in at least partial closure of the opening. Opening processes that attempt to "snap" the displaced fiber out of plane of the original weft are also likely to degrade the softness of the starting weft. Another problem with open materials is that when they are incorporated into final products such as using adhesives, due to their open structure, adhesives will often quickly penetrate through the openings in the material from the bottom to the top, exposed surface, therefore creating unwanted problems such as build-up of adhesive in the converting process or creating unintended joints between layers within the finished product.
[6] There still remains a need for an absorbent article that can adequately reduce the incidence of leakage of bodily secretions from the absorbent article. There still remains a need for an absorbent article that can provide improved handling of bodily secretions. There still remains a need for an absorbent article that can minimize the amount of bodily secretions in contact with the wearer's skin. There still remains a need for an absorbent article that can provide physical and emotional comfort to the wearer of the absorbent article. SUMMARY
[7] In one application, an absorbent article may have an outer covering, an absorbent body, a body-facing material, an acquisition layer positioned between the absorbent body and the body-facing material, and a body-facing material transfer layer. fluid positioned between the acquisition layer and the absorbent body. In such an embodiment, the fluid transfer layer can contain a polymeric material. In such an application, the body facing material may have a backing layer and a projection layer. In such an application, the projection layer may have an inner and an outer surface and may have a plurality of hollow projections extending from the outer surface of the projection layer. In various embodiments, the capture layer may contain fibers having a denier greater than approximately 5. In various embodiments, the material in contact with the body of the absorbent product may further contain a landing area with an open area greater than approximately 1% within a chosen area of the material in contact with the body, projections less than approximately 1% of open area within a chosen area of the material in contact with the body, various fibers of the projection layer entangled with the support layer, a load greater than approximately 2 Newtons per 25mm wide at 10% machine direction extension, projections greater than approximately 1mm in height, a resilience greater than approximately 70%, and combinations of these. In various applications, the absorbent body can be free of superabsorbent material. In various applications, the absorbent body can be more than about 15% superabsorbent material. In many applications, the open area of the projections may be due to fiber-to-fiber interstitial spacing. In many applications, the open area of the deposit areas can be due to fiber-to-fiber interstitial spacing. In various embodiments, the spreading area of the fecal material residue simulacrum in the material in contact with the body shortly after the emission of the fecal material residue simulacrum, in accordance with the test method described in this document, can be less than approximately 34 cm2.
[8] In one embodiment, an absorbent product may have an outer covering, an absorbent body, a material in contact with the body with landing area with an open area greater than 5% within a selected area of the material in contact with the body, a pickup layer positioned between the absorbent body and the material in contact with the body, and a fluid transfer layer positioned between the pickup layer and the absorbent body. In such an embodiment, the fluid transfer layer can contain a cellulosic material. In such an application, the body facing material may have a backing layer and a projection layer. In such an embodiment, the projection layer may contain an inner surface and an outer surface, and may contain several hollow projections extending from the outer surface of the projection layer, where the projections have less than 1% open area inside. of a chosen area of material in contact with the body. In various embodiments, the capture layer may contain fibers with a denier greater than approximately 5. In many applications, the acquisition layer may have fibers having a thickness on the "denier" scale of less than about 5. In many applications, the body facing material of the absorbent article may further include a plurality of projection layer fibers intertwined with the backing layer, a load of greater than about 2 Newtons per 25mm width at the 10% machine direction extent. , projections having a height greater than about 1 mm, a resilience greater than about 70%, and combinations thereof. In various applications, the absorbent body can be free of superabsorbent material. In various applications, the absorbent body can be more than about 15% superabsorbent material. In many applications, the open area of the projections may be due to fiber-to-fiber interstitial spacing. In various embodiments, the open area of the landing areas is due to the interstitial spacing between the fibers. In various embodiments, the spreading area of the fecal material residue simulacrum in the material in contact with the body shortly after the emission of the fecal material residue simulacrum, in accordance with the test method described in this document, can be less than approximately 34 cm2.
[9] In one application, an absorbent article may have an outer covering, an absorbent body, a body-facing material, an acquisition layer positioned between the absorbent body and the body-facing material, and a body-facing material transfer layer. fluid positioned between the acquisition layer and the absorbent body. In such an embodiment, the fluid transfer layer can contain a cellulosic material. In such an application, the body facing material may have a backing layer and a projection layer. In such an application, the projection layer may have an inner and an outer surface and may have a plurality of hollow projections extending from the outer surface of the projection layer. In various embodiments, the capture layer may contain fibers with a denier greater than approximately 5. In various applications, the acquisition layer may have fibers having a thickness on the "denier" scale of less than about 5. In various forms of embodiment, the material in contact with the body of the absorbent product may still contain several fibers from the projection layer entangled with the backing layer, a load greater than approximately 2 Newtons per 25 mm width at 10% machine direction extension, projections greater than approximately 1 mm in height, projections with less than 1% open area within a chosen area of material in contact with the body, a resilience greater than approximately 70%, and combinations of these. In various embodiments, the body-contacting material may have a landing area and the landing area may have an open area greater than approximately 1% within a selected area of the body-contacting material. In various applications, the absorbent body can be free of superabsorbent material. In various applications, the absorbent body can be more than about 15% superabsorbent material. In various embodiments, the open area of the projections is due to the interstitial spacing between the fibers. In various embodiments, the open area of the landing areas is due to the interstitial spacing between the fibers. In various embodiments, the spreading area of the fecal material residue simulacrum in the material in contact with the body shortly after the emission of the fecal material residue simulacrum, in accordance with the test method described in this document, can be less than approximately 34 cm2. BRIEF DESCRIPTION OF THE DRAWINGS
[10] Figure 1 is a side view illustration of an application of an absorbent article.
[11] Figure 2 is a top view of an application of an absorbent article portions cut away for clarity.
[12] Figure 3 is an exploded cross-sectional view of an application of an absorbent article.
[13] Figure 4 is an exploded sectional view of another application of an absorbent article.
[14] Figure 5 is an exploded cross-sectional view of another application of an absorbent article.
[15] Figure 6 is an exploded cross-sectional view of another application of an absorbent article.
[16] Figure 7 is a perspective view of an application of a material facing the body.
[17] Figure 8 is a cross-sectional view of the material facing the body of Figure 7 taken along line 8-8.
[18] Figure 9 is a cross-sectional view of the body-facing material of Figure 7 taken along line 8-8 of Figure 7 showing possible directions of fiber movement within the body-facing material due to a process of fluid intertwining.
[19] Figure 10 is a photomicrograph at a 45-degree angle showing a body-facing material entangled by fluid.
[20] Figure 10A and 10B are photomicrographs showing a cross-section of a material facing the body.
[21] Figure 11A is a top view of an illustrative application of a projection layer of a body-facing material in which two projections are partially aligned with each other.
[22] Figure 11B is a top view of an illustrative application of a projection layer of a body-facing material in which two projections are completely aligned with each other.
[23] Figure 11C is a top view of an illustrative application of a projection layer of a body-facing material in which two projections are completely non-aligned with each other.
[24] Figure 12 is a schematic side view of an apparatus and process for forming a fluid-entangled body facing material.
[25] Figure 12A is an exploded view of a representative portion of a projection forming surface.
[26] Figure 13 is a schematic side view of an alternative application of an apparatus and process for forming a fluid-entangled body facing material.
[27] Figure 14 is a schematic side view of an alternative application of an apparatus and process for forming a fluid-entangled body facing material. The process illustrated in Figure 14 is an adaptation of the apparatus and process illustrated in Figure 13 as well as subsequent Figures 15 and 17.
[28] Figure 15 is a schematic side view of an alternative application of an apparatus and process for forming a fluid-entangled body facing material.
[29] Figure 16 is a schematic side view of an alternative application of an apparatus and a process for forming a fluid-entangled body facing material.
[30] Figure 17 is a schematic side view of an alternative application of an apparatus and process for forming a fluid-entangled body facing material.
[31] Figure 18 is a perspective view of an application of an absorbent article.
[32] Figure 19 is a top view of an application of an absorbent article.
[33] Figure 20 is a perspective view of an exemplary illustration of an imaging system configuration used to determine percent open zone.
[34] Figure 21 is a perspective view of an exemplary illustration of an imaging system configuration used to determine projection height.
[35] Figure 22 is a graph representing tissue thickness as a function of the proportion of overfeed of the projection layer in a forming process.
[36] Figure 23 is a graph depicting the length of fabric with a 10N load as a function of the proportion of overfeed of the projection layer in the process of forming body-facing materials and unsupported projection layers.
[37] Figure 24 is a graph plotting the load in Newtons per 50 mm width as a function of percent extension comparing a body-facing material and an unsupported projection layer.
[38] Figure 25 is a graph plotting the load in Newtons per 50 mm width as a function of percentage extension for a series of body-facing materials by varying the proportion of overfeed.
[39] Figure 26 is a graph plotting the load in Newtons per 50 mm width as a function of percent extension for a series of 45 gsm projection layers while varying the overfeed ratio.
[40] Figure 27 is a photomicrograph on a top view of a specimen designated code 3-6 in Table 1 of the specification.
[41] Figure 27A is a photomicrograph of a sample designated with code 3-6 in Table 1 of the specification taken at a 45-degree angle.
[42] Figure 28 is a top view photomicrograph of a specimen designated with code 5-3 in Table 1 of the specification.
[43] Figure 28A is a photomicrograph of a sample designated with code 5-3 in Table 1 of the specification taken at a 45 degree angle.
[44] Figure 29 is a photomicrograph showing the juxtaposition of a portion of a body-facing material with and without a backing layer supporting the projection layer having been processed simultaneously in the same apparatus.
[45] Figure 30 is a perspective view of an exemplary illustration of a Digital Thickness Gauge setup.
[46] Figure 31 is a side view of an exemplary illustration of an injection apparatus configuration.
[47] Figure 32 is a perspective view of an exemplary illustration of a configuration of the injection apparatus of Figure 31.
[48] Figure 33 is a perspective view of an exemplary illustration of an imaging system configuration.
[49] Figure 34 is a top view of an exemplary illustration of a vacuum box configuration.
[50] Figure 35 is a side view of the exemplary vacuum box illustration of Figure 34.
[51] Figure 36 is a rear view of the exemplary vacuum box illustration of Figure 34.
[52] Figure 37 is a graph representing the spread area of the faecal material simulator in various absorbent compounds.
[53] Figure 38 is a graph representing the spread area of the faecal material simulator on various absorbent compounds.
[54] Figure 39 is a graph representing the spread area of the faecal material simulator in various absorbent compounds.
[55] Figure 40 is a graph representing the residual amount of fecal material simulant in various absorbent compounds.
[56] Figure 41 is a graph representing the residual amount of fecal material simulant in various absorbent compounds.
[57] Figure 42 is a graph depicting the residual amount of fecal material simulant in various absorbent compounds.
[58] Figure 43 is a graph representing the residual amount of fecal material simulant in various absorbent compounds.
[59] Figure 44 is a graph depicting compressive stress versus thickness for an unsupported projection layer and two materials facing the body under a load and unload cycle.
[60] Figure 45 is a graph plotting load (N/25mm) versus percent extension for an unsupported projection layer and two different body facing materials.
[61] Figure 46 is a top view of an application of a rate <> block.
[62] Figure 46A is a cross-sectional view of the rate block of Figure 46. DETAILED DESCRIPTION
[63] In one application, the present disclosure is generally directed to an absorbent article that may have improved control of bodily secretions. In one application, the present disclosure is generally directed to an absorbent article containing a body-facing material that may have hollow projections extending from a surface of the body-facing material. Without being bound by theory, it is believed that several attributes can be obtained from providing hollow projections to the material facing the body. First, by providing a body facing material with hollow projections, the body facing material can have a higher degree of thickness while minimizing the amount of material used. The increased thickness body facing material can improve separation between the wearer's skin and the absorbent body of an absorbent article, thereby improving the prospect of drier skin. By providing projections, deposition areas can be created between the projections that can temporarily drive away bodily secretions from high points of the projections while body secretions can be absorbed by the absorbent article. Providing projections, therefore, can reduce skin contact with the body's secretion and provide better skin benefits. Second, by providing projections, the spreading of bodily secretions onto the body facing material of the absorbent article can be reduced thereby exposing less skin to contamination. Third, by reducing total skin contact, a body facing material with projections can provide a softer feel to the contacted skin, thereby enhancing the tactile aesthetics of the body facing material and absorbent article. Fourth, when materials with projections are used as a body facing material for an absorbent article, the body facing material can also serve the function of acting as a cleaning aid when the absorbent article is removed from the wearer. Definitions:
[64] The term "absorbent article"' refers here to an article that can be placed against or in close proximity to the user's body (ie, adjacent to) to absorb and contain various discharged liquid, solid, and semi-solid secretions Such absorbent articles, as described herein, are intended to be disposed of after a limited period of use rather than being washed or otherwise restored for reuse. It should be understood that the present disclosure is applicable to various disposable absorbent articles , including, but not limited to, diapers, workout pants, youth pants, swim pants, feminine hygiene products, including, but not limited to, menstrual pads, incontinence products, medical apparel, compresses and bandages, other apparel for personal care or health and the like without departing from the scope of this disclosure.
[65] The term "acquisition layer" refers here to a layer capable of accepting and temporarily retaining bodily fluid secretions to slow down and diffuse a jet or squirt of bodily fluid secretions and subsequently release the bodily fluid secretions from this into another layer or layers of the absorbent article.
[66] The term "joined" herein in this document refers to joining, adhering, connecting, fastening, or the like, of two elements. Two elements will be considered linked when they are joined, adhered, connected, attached, or the like, directly to each other or indirectly to each other, as when each is directly linked to intermediate elements.
[67] The term "carded weft" refers herein to a weft containing natural or synthetic fibers of standard length typically containing fibers of less than about 100 mm in length. Natural fiber bales can undergo an opening process to separate the fibers which are then sent to a carding process which separates and combs the fibers to align them in the machine direction, after which the fibers are deposited onto a moving yarn for further processing. These webs are usually subjected to some type of bonding process, such as thermal bonding using heat and/or pressure. In addition, or instead, the fibers can be subjected to adhesive processes to bond the fibers, for example, by the use of powder adhesives. The carded web can be subjected to fluid entanglement, such as hydroentanglement, to further entangle the fibers and thereby improve the integrity of the carded web. Carded wefts, due to machine direction fiber alignment, once bonded, will typically have greater machine direction strength than cross machine direction strength.
[68] The term "film" here refers to a thermoplastic film manufactured using an extrusion and/or molding process, such as a cast film or blown film extrusion process. The term includes perforated films, cut films, and other porous films that constitute liquid transfer films, as well as films that do not transfer fluids, such as, but not limited to, barrier films, filled films, breathable films, and oriented films.
[69] The term "fluid entangled" and "fluid entangled" here refer to a forming process to further increase the degree of interlacing within the fiber of a given fibrous non-woven web or between fibrous non-woven webs. fabric and other materials in order to make the separation of individual fibers and/or layers more difficult as a result of interweaving. Generally this is achieved by supporting the fibrous non-woven web on some type of forming or carrier surface that has at least some degree of permeability to the collision of pressurized fluid. A stream of pressurized fluid (generally multiple streams) can then be directed against the surface of the non-woven web which is opposite the supporting surface of the web. The pressurized fluid contacts the fiber portions and forces the fibers in the direction of fluid flow, thereby displacing all or a portion of a plurality of fibers toward the supported surface of the web. The result is an additional interweaving of fibers in what might be called the weft's Z direction (its thickness) relative to its most planar dimension, its X-Y plane. When two or more separate webs or other layers are placed adjacent to each other on the forming/conveyor surface and subjected to pressurized fluid, the generally desired result is that some of the fibers from at least one of the webs are forced into the adjacent web or layer, causing, therefore the interweaving of fiber between the interfaces of the two surfaces so as to cause bonding or joining of the webs/layers due to the greater interweaving of the fibers. The degree of bonding or interweaving will depend on a number of factors, including, but not limited to, types of fibers being used, fiber lengths, the degree of pre-bonding or interweaving of the weft or wefts prior to subjection to the process. of fluid weave, the type of fluid being used (liquids such as water, steam or gas such as air), fluid pressure, number of fluid flows, process speed, fluid residence time and the porosity of the weft or wefts/other layers and the forming/conveying surface. One of the more common fluid entanglement processes is referred to as hydroentanglement, which is a process well known to those skilled in the art of non-woven webs. Examples of the fluid entanglement process can be found in US Patent No. 4,939,016 to Radwanski et al, US Patent No. 3,485,706 to Evans, and European Patent Nos. 4,970,104 and 4,959. 531 to Radwanski, each of which is incorporated herein in its entirety by reference thereto for all purposes.
[70] The term "g/cc" here refers to grams per cubic centimeter.
[71] The term "gsm" here refers to grams per square meter.
[72] The term "hydrophilic" here refers to fibers or surfaces that are wetted by aqueous liquids in contact with the fibers. The degree of wetting of materials can, in turn, be described in terms of contact angles and the surface tensions of the liquids and materials involved. Appropriate equipment and techniques for measuring the wettability of particular fiber materials or fiber material mixtures may be provided by the Surface Strength Analyzer System (Cahn SFA-222), or a substantially equivalent system. When measured with this system, fibers with contact angles less than 90 are designated "wettable" or hydrophilic and fibers having contact angles greater than 90 are designated "non-wettable" or hydrophobic.
[73] The term "liquid impervious" here refers to a layer or laminate of several layers in which bodily liquid secretions, such as urine, will not pass through the layer or laminate, under normal use, in a direction generally perpendicular to the layer plane or laminate at the point of contact with the liquid.
[74] The term "liquid permeable" here refers to any material that is not impermeable to liquid.
[75] The term "fused and blown" herein refers to fibers formed by extrusion of a molten thermoplastic material through a plurality of thin, generally circular, capillaries such as melted wires or filaments in convergence with heated gas at high velocity. (eg, air) which attenuates the filaments of the molten thermoplastic material to reduce its diameter, which can be a microfiber diameter. Consequently, the fused and blown fibers are transported by the high velocity gas flow and are deposited onto a collecting surface to form a web of randomly dispersed fused and blown fibers. Such a process is disclosed, for example, in US Patent No. 3,849,241 to Butin et al, which is incorporated herein by reference. Fused and blown fibers are microfibers that can be continuous or discontinuous, are generally less than a thickness on the "denier" scale of about 0.6, and can be tacky and self-bonding when deposited on a collecting surface.
[76] The term "non-woven" herein in this document refers to materials and material webs that are formed without the aid of a textile weaving or knitting process. Materials and material webs may have a structure of individual fibers, or yarns (collectively referred to as "fibers") which may be intermediate, but not in an identifiable manner as a knitted fabric. Non-woven materials or wefts can be formed from many processes such as, but not limited to, cast and blown processes, spin bonding processes, carded weft processes, etc.
[77] The term "soft" herein in this document refers to materials that are compatible and will readily conform to the general shape and contours of the user's body.
[78] The term "spunbonded" herein herein refers to small diameter fibers that are formed by extrusion of molten thermoplastic material as filaments from a plurality of thin capillaries of a spinnerette having a circular or circular configuration. another, with the diameter of the extruded filaments then being rapidly reduced by a conventional process such as, for example, drawing draw and processes described in U.S. Patent No. 4,340,563 to Appel et al., U.S. Patent No. 3,692,618 to Dorschner et al., United States Patent No. 3,802,817 to Matsuki et al, United States Patent No. 3,338,992 and 3,341,394 to Kinney, United States Patent No. 3,502. 763 to Hartmann, United States Patent No. 3,502,538 to Peterson, and United States Patent No. 3,542,615 to Dobo et al., each of which is incorporated herein in its entirety by reference. Spin-joined fibers are generally continuous and often have an average thickness on the "denier" scale greater than about 0.3 and in one application, between about 0.6, 5 and 10 and about 15, 20 and 40. Spin-joined fibers generally they are non-adherent when they are deposited on a collecting surface.
[79] The term "superabsorbent" here refers to a water-swellable, water-insoluble, organic or inorganic material capable, under the most favorable conditions, of absorbing at least about 15 times its weight and, in one application, at least about 30 times its weight, in an aqueous solution containing 0.9 percent by weight sodium chloride. Superabsorbent materials can be natural, synthetic and modified polymers and materials. In addition, superabsorbent materials can be inorganic materials such as silica gel or organic compounds such as crosslinked polymers.
[80] The term "thermoplastic" refers here to a material that softens and can be molded when exposed to heat and that substantially returns to an unsoftened condition when cooled. Absorbent article:
[81] Referring to Figure 1, a disposable absorbent article 10 of the present disclosure is exemplified in the form of a diaper. It should be understood that the present disclosure is suitable for use with various other absorbent personal care articles, such as feminine hygiene products, without departing from the scope of the present disclosure. While the applications and illustrations described herein may generally apply to absorbent articles manufactured in the longitudinal product direction, which is hereinafter referred to as machine direction manufacturing of a product, it should be noted that a person with basic knowledge could apply the information. herein in this document for absorbent articles manufactured in the latitudinal direction of the product which is hereinafter referred to as manufacturing in the cross direction of a product without departing from the spirit and scope of the disclosure. The absorbent article 10 illustrated in Figure 1 includes a front waist region 12, a rear waist region 14 and a genital region 16 interconnecting the front and back waist regions 12 and 14, respectively. The absorbent article 10 has a pair of longitudinal side edges 18 and 20 (shown in Figure 2) and a pair of opposing waist edges, respectively designated waist front edge 22 and waist rear edge 24. be contiguous with the front waist edge 22 and the rear waist region 14 may be contiguous with the rear waist edge 24.
[82] Referring to Figure 2, a non-limiting illustration of an absorbent article 10, such as a diaper, is illustrated in a top view with portions cut away for clarity of illustration. The absorbent article 10 may include an outer covering 26 and a body facing material 28. In one application, the body facing material 28 may be joined to the outer covering 26 in an overlapping relationship by any suitable means, such as, for example, but not limited to, adhesives, ultrasonic bonds, thermal bonds, pressure bonds or other conventional techniques. The outer covering 26 may define a length, or longitudinal direction 30 and a width or lateral direction 32, which, in the illustrated application, may match the length and width of the absorbent article 10. The longitudinal direction 30 and lateral direction 32 of the article The absorbent article 10 and the materials forming the absorbent article 10 can provide the XY planes, respectively, of the absorbent article 10 and the materials forming the absorbent article 10. The absorbent article 10 and the materials forming the absorbent article 10 may also be have a Z-direction. Measurement, taken under pressure, in the Z direction of a material that forms the absorbent article 10 can provide a measure of the thickness of the material. The measurement, taken under pressure, in the Z direction of the absorbent article 10 can provide a measurement of the volume of the absorbent article 10.
[83] Referring to Figures 2 - 6, an absorbent body 40 may be disposed between the outer covering 26 and the material facing the body 28. The absorbent body 40 may have longitudinal edges, 42 and 44, which in a application, may form longitudinal side edge portions, 18 and 20, respectively, of the absorbent article 10 and may have opposite end edges, 46 and 48, which, in one application, may form waist edge portions, 22 and 24, respectively, of the absorbent article 10. In one application, the absorbent body 40 may have a length and width that are equal to or less than the length and width of the absorbent article 10. In one application, a pair of containment tabs, 50 and 52 , may be present and may inhibit the lateral flow of bodily secretions.
[84] The front waist region 12 may include the absorbent article portion 10 which, when worn, is positioned at least in part in front of the wearer while the rear waist region 14 may include the absorbent article portion 10 which, when worn, used, is positioned at least partly to the rear of the user. The genital region 16 of the absorbent article 10 may include the portion of the absorbent article 10 which, when worn, is positioned between the wearer's legs and may partially cover the wearer's lower torso. Waist edges 22 and 24 of the absorbent article 10 are configured to encircle the wearer's waist and together define the central waist opening 54 (as shown in Figure 1). Portions of the longitudinal side edges, 18 and 20, in the genital region 16 may generally define leg openings 56 (as shown in Figure 1) when the absorbent article 10 is worn.
[85] The absorbent article 10 may be configured to contain and/or absorb liquid, solid and semi-solid bodily secretions discharged from the wearer. For example, containment flaps, 50 and 52, can be configured to provide a barrier to the lateral flow of bodily secretions. An elastic tab component, 58 and 60, can be operatively joined to each containment tab, 50 and 52, in any suitable manner known in the art. The elasticized containment tabs 50 and 52 may define a partially released edge which may assume a vertical configuration in at least the genital region 16 of the absorbent article 10 to form a seal against the wearer's body. The containment tabs 50 and 52 may be located along the longitudinal side edges 18 and 20 of the absorbent article 10, and may extend longitudinally along the entire length of the absorbent article 10 or may extend partially along the length of the absorbent article. of absorbent article length 10. Suitable construction and arrangements for the containment flaps, 50 and 52, are generally well known to those skilled in the art and are described in U.S. Patents 4,704,116 filed November 3, 1987, to Yes and No. 5,562,650 filed October 8, 1996 to Everett et al, which are incorporated herein by reference.
[86] In many applications, the absorbent article 10 may include a secondary liner 34 (as exemplified in Figure 4 and Figure 6). In such applications, the secondary liner 34 may have a body facing surface 36 and a garment facing surface 38. In such applications, the body facing material 28 may be bonded to the body facing surface 36 of the secondary liner 34.
[87] To further enhance the containment and/or absorption of bodily secretions, the absorbent article 10 may suitably include a front elastic waist element 62, a rear elastic waist element 64, and elastic leg elements 66 and 68. as known to technicians. Elastic waist elements 62 and 64 may be secured to outer shell 26, body facing material 28, and/or secondary liner 34 along opposing waist edges 22 and 24 and may extend along of part or all of the waist edges, 22 and 24. The elastic leg elements, 66 and 68, can be attached to the outer shell 26, the material facing the body 28, and/or the secondary lining 34 along the opposite longitudinal side edges 18 and 20 and positioned in the genital region 16 of the absorbent article 10.
[88] In various applications, the material facing the body 28 of an absorbent article 10 can have a load of more than about 2 Newtons per 25 mm wide at a 10% stretch in the machine direction as measured using the method. "Load Versus Percentage of Extent" test test described here in this document. In various applications, the material facing the body 28 may have projections, which have a height greater than about 1 mm as measured using the test method "Method for Determining the Height of Projections" described herein. In various applications, the body facing material 28 of an absorbent article 10 can have a resilience greater than about 70% as measured using the "Percent Resilience - One Compression Cycle" test method described herein. In various applications, the amount of residual fecal material simulator in the material facing the body 28 of the absorbent article 10 after etching with fecal material simulator may be less than about 2.5 grams as measured using the "Determination" test method of Fecal Waste Material Simulator" described here in this document. In various applications, the spread area of the faecal material simulator in the material facing the body 28 of the absorbent article 10 after etching with faecal material simulator may be less than about 34 cm2, measured using the "Determination" test method of the Fecal Material Simulator Spreading Area", described here in this document. In various applications, the body-facing material 28 may have projections 90 that have less than 1% open zone in a chosen area of the body-facing material 28 as measured using the "Method for Determining Area Percentage" test method Open", described here in this document. In various applications, the body facing material 28 may have a deposit area 116 which may have more than about 1% open area in a selected area of the body facing material 28 as measured using the "Method" test method to Determine Percent Open Area", described here in this document. In various applications, the entry time for a second entry through a body facing material 28 onto an absorbent article 10 after etching with a menstruation simulator may be less than commercially available absorbent articles as measured using the test method. Input/Rewetting steps described here in this document. In various applications, the entry time for a second entry through a body facing material 28 into an absorbent article 10 can be from about 25 or 30% to about 50, 60 or 70% less than the time of products. commercially available post attack with a menstruation simulator as measured using the Entry/Rewet test method described herein. In various applications, the entry time for a second entry through a body facing material 28 into an absorbent article 10 may be less than 30 seconds after an attack of a menstruation simulator as measured using the Entry/Entry test method. Rewetting described here. In various applications, the material facing the body 28 may have a deposit area 116 with a percentage open area greater than the percentage open area of a projection of 90 as measured in accordance with the test method "Method for Determining o Percent Open Area", described here in this document.
[89] Additional details on each of these elements of the absorbent article 10 described herein can be found below and with reference to the Figures. External Coverage:
[90] Outer casing 26 may be breathable and/or impervious to liquids. The outer covering 26 can be elastic, stretchable or non-stretchable. The outer covering 26 can be constructed of a single layer, multiple layers, laminates, spin-bonded fabrics, films, cast and blown fabrics, elastic mesh, microporous webs, joined carded webs, or foams provided by the elastomeric or polymeric materials. In one application, for example, the outer shell 26 can be constructed of a microporous polymeric film such as polyethylene or polypropylene.
[91] In one application, the outer covering 26 may be a single layer of a liquid impermeable material. In one application, the outer covering 26 may be suitably stretchable and more suitably elastic, in at least the lateral or circumferential direction 32 of the absorbent article 10. In one application, the outer covering 26 may be stretchable and more suitably elastic, both in the side 32 and in longitudinal directions 30. In one application, the outer covering 26 may be a multi-layer laminate in which at least one of the layers is liquid impervious. In an application as illustrated in Figures 3 - 6, the outer covering 26 may be a two-layer construction, including an outer layer material 70 and an inner layer material 72 which can be joined together by a laminated adhesive. Suitable laminated adhesives can be applied continuously or intermittently as grains, a spray, parallel spiral, or the like. Suitable adhesives are available from Bostik Findlay Adhesives, Inc. of Wauwatosa, WI, USA. It should be understood that the inner layer 72 can be joined to the outer layer 70 using ultrasonic bonds, thermal bonds, pressure bonds or the like.
[92] The outer layer 70 of the outer covering 26 may be of any suitable material and may be a material that provides a generally fabric-like texture or appearance to the wearer. An example of such a type of material might be a carded web bonded from 100% polypropylene with a diamond bond pattern available from Sandler A.G., Germany, as 30 gsm Sawabond 4185 ® or equivalent. Another example of a material suitable for use as an outer layer 70 of an outer covering 26 may be a 20 gsm spunbond polypropylene nonwoven web. Outer layer 70 may also be constructed of the same materials from which secondary liner 34 may be constructed as described herein.
[93] The liquid-impervious inner layer 72 of the outer shell 26 (or the liquid-impermeable outer shell 26 where the outer shell 26 is of a single-layer construction) may be vapor permeable (i.e., "breathable") or waterproof to steam. The liquid impermeable inner layer 72 (or the liquid impermeable outer cover 26 where the outer cover 26 is of a single layer construction) can be fabricated from a thin plastic film, although other liquid impervious materials may also be used. The liquid impervious inner layer 72 (or liquid impervious outer cover 26 where the outer cover 26 is of a single layer construction) can inhibit liquid bodily secretions from leaking from the absorbent article 10 and wetting articles such as sheets and clothing as well. as the user and caregiver. An example of a material for a liquid impervious inner layer 72 (or the liquid impervious outer cover 26 where the outer cover 26 is of a single layer construction) may be a Berry Plastics XP - 8695H film printed with 19 gsm or equivalent. commercially available from Berry Plastics Corporation, Evansville, IN, United States of America.
[94] Where outer covering 26 is of a single layer construction, it may be patterned and/or finished to provide a more fabric-like texture or appearance. The outer covering 26 can allow the escape of vapors from the absorbent article 10 while preventing the passage of liquids. A liquid-impermeable, vapor-permeable material can be composed of a microporous polymer film or a non-woven material that has been coated or otherwise treated to impart a desired level of liquid impermeability. Absorbent Body:
[95] The absorbent body 40 can be suitably constructed to be generally compressible, conformable, pliable, non-irritating to the wearer's skin, and capable of absorbing and retaining liquid bodily secretions. The absorbent body 40 can be manufactured in a wide variety of sizes and shapes (eg, rectangular, trapezoidal, T-shaped, I-shaped, hourglass-shaped, etc.) and a wide variety of materials. The size and capacity of the absorbent body 40 must be compatible with the size of the intended wearer and the liquid load imparted by the intended use in the absorbent article 10. In addition, the size and capacity of the absorbent body 40 can be varied to accommodate varying users. from children to adults.
[96] The absorbent body 40 can have a length ranging from about 150, 160, 170, 180, 190, 200, 210, 220, 225, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, or 350 mm to about 355, 360, 380, 385, 390, 395, 400, 410, 415, 420, 425, 440, 450, 460, 480, 500, 510 or 520 mm . The absorbent body 40 can have a genital area width ranging from about 30, 40, 50, 55, 60, 65 or 70 mm to about 75, 80, 85, 90, 95, 100, 105, 110, 115 , 120, 125, 130, 140, 150, 160, 170 or 180 mm. The width of the absorbent body 40 located within the front waist region 12 and/or the rear waist region 14 of the absorbent article 10 can range from about 50, 55, 60, 65, 70, 75, 80, 85, 90 or 95 mm to about 100, 105, 110, 115, 120, 125 or 130 mm. As noted herein, absorbent body 40 may have a length and width which may be less than or equal to the length and width of absorbent article 10.
[97] In one application, the absorbent article 10 can be a diaper containing the following ranges of lengths and widths of an absorbent body 40 containing an hourglass shape: the length of the absorbent body 40 can range from about 170, 180, 190, 200, 210, 220, 225, 240 or 250 mm to about 260, 280, 300, 310, 320, 330, 340, 350, 355, 360, 380, 385 or 390 mm; the width of the absorbent body 40 in the genital region 16 can range from 40, 50, 55, or 60 mm to about 65, 70, 75 or 80 mm; the width of the absorbent body 40 in the front waist region 12 and/or rear waist region 14 can range from 80, 85, 90, or 95 mm to about 100, 105, or 110 mm.
[98] In one application, the absorbent article 10 can be a training pants or youth pants containing the following ranges of lengths and widths of an absorbent body 40 containing an hourglass shape: the length of the absorbent body 40 can vary by about from 400, 410, 420, 440 or 450 mm to about 460, 480, 500, 510 and 520 mm; the width of the absorbent body 40 in the genital region 16 can range from about 50, 55, 60 mm to about 65, 70, 75 or 80 mm; the width of the absorbent body 40 in the front waist region 12 and/or rear waist region 14 can range from about 80, 85, 90, or 95 mm to about 100, 105, 110, 115, 120, 125 or 130 mm.
[99] In one application, the absorbent article 10 can be an adult incontinence garment containing the following ranges of lengths and widths of an absorbent body 40 containing a rectangular shape: the length of the absorbent body 40 can range from about 400, 410 or 415 to about 425 or 450 mm; the width of the absorbent body 40 in the genital region 16 can range from about 90 or 95 mm to about 100, 105, or 110 mm. It should be noted that the absorbent body 40 of an adult incontinence garment may or may not extend into one or both of the front waist region 12 or rear waist region 14 of the absorbent article 10.
[100] In one application, the absorbent article 10 can be a feminine hygiene product containing the following length and width ranges of the absorbent body 40 containing an hourglass shape: The length of the absorbent body 40 can range from about 150, 160 , 170 or 180 mm to about 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310 or 320 mm; the width of the absorbent body in the genital region 16 can range from 30, 40 or 50 mm to about 60, 70, 80, 90 or 100 mm.
[101] The absorbent body 40 may have two surfaces, 74 and 76, such as a user-facing surface 74 and a garment-facing surface 76. Edges, such as the longitudinal side edges, 42 and 44, and front end edges and rear, 46 and 48, can connect the two surfaces, 74 and 76.
[102] In one application, the absorbent body 40 can be composed of a weft material of hydrophilic fibers, cellulosic fibers (eg, cellulose pulp fibers), natural fibers, synthetic fibers, woven or non-woven sheets, fabric of open web or other stabilizing structures, superabsorbent material, binder materials, surfactants, selected hydrophobic and hydrophilic materials, pigments, lotions, odor control agents or the like, as well as combinations thereof. In one application, the absorbent body 40 can be a matrix of fluff cellulose and superabsorbent material.
[103] In one application, the absorbent body 40 may be constructed of a single layer of materials, or alternatively, it may be constructed of two layers of materials or more. In an application in which the absorbent body 40 has two layers, the absorbent body 40 may have a user-facing layer suitably composed of hydrophilic fibers and a garment-facing layer suitably composed at least in part of a high-absorptive material. , commonly known as superabsorbent material. In such an application, the wearer facing layer of absorbent body 40 may suitably be composed of fluff cellulose, such as fluff cellulose pulp, and the garment facing layer of absorbent body 40 may suitably be composed of superabsorbent material, or a blend. of fluff cellulose and superabsorbent material. As a result, the wearer facing layer may have lower absorbent capacity per unit weight than the garment facing layer. The user-facing layer may alternatively be composed of a mixture of hydrophilic fibers and superabsorbent material, while the concentration of superabsorbent material present in the user-facing layer is less than the concentration of superabsorbent material present in the garment-facing layer. so that the wearer facing layer may have a lower absorbent capacity per unit weight than the garment facing layer. It is also envisioned that the garment facing layer may be composed solely of superabsorbent material without departing from the scope of this disclosure. It is also anticipated that, in an application, each of the layers, the wearer-facing and garment-facing layers, may have a superabsorbent material such that the absorbent capacity of the two superabsorbent materials may be different and can provide the absorbent body 40 a lower absorbent capacity in the wearer-facing layer than in the garment-facing layer.
[104] Various types of hydrophilic wettable fibers can be used in the absorbent body 40. Examples of suitable fibers include natural fibers, cellulosic fibers, synthetic fibers composed of cellulose and cellulose derivatives such as rayon fibers; inorganic fibers composed of an inherently wettable material such as glass fibers; synthetic fibers made from inherently wettable thermoplastic polymers, such as particular polyester or polyamide fibers, or composed of non-wettable thermoplastic polymers, such as polyolefin fibers that have been hydrophilized by suitable means. Fibers can be hydrophilized, for example, by treating with a surfactant, treating with silica, treating with a material that has a suitable hydrophilic molarity and is not easily removed from the fiber, or by coating the non-wettable hydrophobic fiber with a hydrophilic polymer during or after fiber formation. For example, a suitable type of fiber is a cellulose pulp which is a highly absorbent sulphate cellulose pulp containing mainly long wood fibers. However, cellulose pulp can be exchanged with other fiber materials such as synthetic, polymeric, or blown and blown fibers or with a combination of natural and blown and blown fibers. In one application, the fluff cellulose may include a fluff cellulose pulp blend. An example may be a fluff cellulose pulp "CoosAbsorbTM S Fluff Pulp" or equivalent available from Abitibi Bowater, Greenville, SC, United States of America, which is a bleached highly absorbent sulfate cellulose pulp containing primarily long fiber cellulose fibers. south.
[105] The absorbent body 40 can be formed with a dry forming technique, an air forming technique, a wet forming technique, a foaming technique, or the like, as well as combinations of these. A coformed non-woven material can also be employed. Methods and apparatus for performing such techniques are well known in the art.
[106] Suitable superabsorbent materials can be selected from natural, synthetic and modified polymers and materials. Superabsorbent materials can be inorganic materials, such as silica gel, or organic compounds, such as crosslinked polymers. Crosslinking can be covalent, ionic, Van der Waals, or hydrogen bonding. Typically, a superabsorbent material may be able to absorb at least about ten times its weight in liquid. In one application, the superabsorbent material can absorb more than twenty-four times its weight in liquid. Examples of superabsorbent materials include polyacrylamides, polyvinyl alcohol, ethylene maleic anhydride copolymers, polyvinyl ethers, hydroxypropyl cellulose, carboxymal methyl cellulose, polyvinylmorpholinone, vinyl sulfonic acid polymers and copolymers, polyacrylates, polyacrylamides, polyvinyl pyrrolidone, and the like. Additional polymers suitable for superabsorbent materials include acrylonitrile grafted hydrolyzed starch, acrylic acid grafted starch, polyacrylates and copolymers of isobutylene maleic anhydride and mixtures thereof. The superabsorbent material can be in the form of discrete particles. The discrete particles can be of any desired shape, e.g. spiral or semi-spiral, cubic, rod-like, polyhedron, etc. Shapes containing a largest/smallest dimension ratio such as needles, flakes and fibers are also contemplated for use herein. Particle conglomerates of superabsorbent materials can also be used in the absorbent body 40.
[107] In one application, the absorbent body 40 may be free of superabsorbent material. In one application, absorbent body 40 can have at least about 15% by weight of a superabsorbent material. In one application, the absorbent body 40 can be at least 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 99 or 100% of the weight of a superabsorbent material. In one application, the absorbent body 40 may have less than about 100, 99, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40 35, 30, 25 or 20% in weight of a superabsorbent material. In one application, the absorbent body 40 can be from about 15, 20, 25, 30, 35, 40, 45, 50, 55 or 60% to about 65, 70, 75, 80, 85, 90, 95, 99 or 100% by weight of a superabsorbent material. Examples of superabsorbent materials include, but are not limited to, FAVOR SXM-9300 or equivalent available from Evonik Industries, Greensboro, NC, United States of America and HYSORB 8760 or equivalent available from BASF Corporation, Charlotte, NC, United States of America
[108] The absorbent body 40 can be superimposed over the inner layer 72 of the outer cover 26, extending laterally between the elastic members of the legs 66 and 68 and can be joined to the inner layer 72 of the outer cover 26 as well as being attached to them with adhesive. However, it should be understood that the absorbent body 40 may be in contact with, and not joined with, the outer covering 26 and remains within the scope of the disclosure. In one application, the outer covering 26 may be composed of a single layer and the absorbent body 40 may be in contact with the single layer of the outer covering 26. In one application, a layer such as, but not limited to, a fluid transfer layer 78, can be positioned between the absorbent body 40 and the outer covering 26. Fluid Transfer Layer:
[109] In various applications, as illustrated in the non-limiting example of Figure 3, an absorbent article 10 may be constructed without a fluid transfer layer 78. In various applications, as illustrated in the non-limiting examples of Figure 4 - 6 , the absorbent article 10 may have a fluid transfer layer 78. The fluid transfer layer 78 may have a wearer facing surface 80 and a garment facing surface 82. In one application, the fluid transfer layer 78 may be in contact with absorbent body 40. In one application, fluid transfer layer 78 may be joined to absorbent body 40. Joining fluid transfer layer 78 to absorbent body 40 may occur by any known means by someone with skills such as, but not limited to, stickers. In one application as illustrated in the non-limiting example of Figure 4, a fluid transfer layer 78 may be positioned between the body facing material 28 and the absorbent core 40. In an application as illustrated in the non-limiting example of Figure 5, a fluid transfer layer 78 can completely encompass the absorbent body 40 and can be sealed to itself. In such an application, the fluid transfer layer 78 may be folded back on itself and then sealed using, for example, heat and/or pressure. In one application, such as in the non-limiting illustration of Figure 6, a fluid transfer layer 78 can be composed of separate sheets of material that can be used to partially or fully enclose absorbent body 40 and that can be sealed together. through a sealing medium such as an ultrasonic weld or other thermochemical bonding means or the use of an adhesive.
[110] In one application, fluid transfer layer 78 may be in contact with and/or joined to the user-facing surface 74 of absorbent body 40. In one application, fluid transfer layer 78 may be in contact with and/or joined to the user-facing surface 74 and at least one of the edges, 42, 44, 46 and/or 48 of the absorbent body 40. In one application, the fluid transfer layer 78 may be in contact with and /or joined to the wearer-facing surface 74, at least one of the edges, 42, 44, 46 and/or 48 and the garment-facing surface 76 of the absorbent body 40. In one application, the absorbent body 40 may be partially or completely surrounded by a fluid transfer layer 78.
[111] The fluid transfer layer 78 may be pliable, less hydrophilic than the absorbent body 40 and sufficiently porous to therefore allow liquid bodily secretions from the body to penetrate through the fluid transfer layer 78 to reach the absorbent body 40. In one application, fluid transfer layer 78 may have sufficient structural integrity to withstand wetting thereof and absorbent body 40. In one application, fluid transfer layer 78 may be constructed from a single layer of material. , or it can be a laminate constructed from two or more layers of material.
[112] In one application, fluid transfer layer 78 may include, but is not limited to, natural and synthetic fibers, such as, but not limited to, polyester, polypropylene, acetate, nylon, polymeric materials, materials cellulosics such as cellulose pulp, cotton, rayon, viscose, LYOCELL®, such as from the Lenzing Company of Austria, or mixtures of these or other cellulosic fibers and combinations thereof. Natural fibers can include, but are not limited to, wool, cotton, linen, hemp and cellulose pulp. Cellulose pulps may include, but are not limited to, the grade of light particles of standard long fiber cellulose such as "CoosAbsorbTM S Fluff Pulp" or equivalent available from Abitibi Bowater, Greenville, SC, United States of America, which is a pulp of bleached, highly absorbent, sulfated cellulose containing mainly southern long fiber cellulose fibers.
[113] In many applications, fluid transfer layer 78 can include cellulosic material. In various applications, fluid transfer layer 78 can be a crepe filler or a high strength fabric. In various applications, fluid transfer layer 78 can include polymeric material. In one application, a fluid transfer layer 78 can include a spunbonded material. In one application, a fluid transfer layer 78 may include a molten and blown material. In one application, the fluid transfer layer 78 may be a laminate of a blown melt non-woven material containing fine fibers laminated to at least one layer of spin-bonded non-woven material containing coarse fibers. In such an application, the fluid transfer layer 78 may be a spunbonded material - cast and blown ("SM"). In one application, the fluid transfer layer 78 may be spin-bonded material - cast and blown - spun-bonded ("SMS"). A non-limiting example of such a fluid transfer layer 78 may be a spun-bonded-cast and blown-spun-bonded material of 10 gsm. In various applications, fluid transfer layer 78 can be composed of at least one material that has been hydraulically woven into a non-woven substrate. In various applications, fluid transfer layer 78 can be composed of at least two materials that have been hydraulically interwoven into a non-woven substrate. In various applications, fluid transfer layer 78 can have at least three materials that have been hydraulically interwoven into a non-woven substrate. A non-limiting example of a fluid transfer layer 78 may be a 33 gsm hydraulically interwoven substrate. In one example, fluid transfer layer 78 may be 33 gsm hydraulically interwoven substrate composed of a 12 gsm spunbonded material, a 10 gsm cellulose pulp material having a length of about 0.6 cm up to about 5.5 cm and a 11 gsm polyester natural fiber material. To manufacture the fluid transfer layer 78 described above, the 12gsm spunbonded material can provide a base layer, while the 10gsm cellulose pulp material and the 11gsm polyester natural fiber material can be homogeneously mixed and deposited onto the spunbonded material and then hydraulically interwoven with the spunbonded material.
[114] In many applications, a wet strength agent may be included in fluid transfer layer 78. A non-limiting example of a wet strength agent may be Kymene 6500 (557LK) or equivalent available from Ashland Inc. of Ashland , KY, United States of America. In many applications, a surfactant may be included in fluid transfer layer 78. In many applications, fluid transfer layer 78 may be hydrophilic. In various applications, fluid transfer layer 78 can be hydrophobic and can be treated in any manner known in the art to be rendered hydrophilic.
[115] In one application, the fluid transfer layer 78 may be in contact and/or joined to an absorbent body 40, which is made at least partially of a particulate material such as a superabsorbent material. In an application where fluid transfer layer 78 at least partially or completely surrounds absorbent body 40, fluid transfer layer 78 should not unduly expand or stretch as this can cause particulate material to escape from absorbent body 40 In one application, the fluid transfer layer 78, while in a dry state, should have respective extension values at peak load in the machine and transverse directions of 30% or less and 40% or less, respectively.
[116] In one application, fluid transfer layer 78 may have a longitudinal length equal to, greater than or less than the longitudinal length of absorbent body 40. Fluid transfer layer 78 may have a longitudinal length ranging from about about 150, 160, 170, 180, 190, 200, 210, 220, 225, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, or 350 mm to about 355, 360, 380, 385, 390, 395, 400, 410, 415, 420, 425, 440, 450, 460, 480, 500, 510 or 520 mm. Acquisition Layer:
[117] In various applications, as illustrated, for example, in Figure 5, the absorbent article 10 may have an acquisition layer 84. The acquisition layer 84 can help to slow and spread jets or squirts of liquid bodily secretions penetrating the material Body Facing 28. In one application, acquisition layer 84 may be positioned between body facing material 28 and absorbent body 40 to receive and deliver bodily secretions for absorption by absorbent body 40. In one application, the layer acquisition 84 may be positioned between the body-facing material 28 and a fluid transfer layer 78 if a fluid transfer layer 78 is present. In one application, acquisition layer 84 may be positioned between a secondary liner 34, if present, and absorbent body 40.
[118] The acquisition layer 84 may have a user-facing surface 86 and a garment-facing surface 88. In one application, the acquisition layer 84 may be in contact with and/or joined to the body-facing material 28. In an application where the acquisition layer 84 is joined to the body facing material 28, bonding of the acquisition layer 84 to the body facing material 28 can occur with the use of an adhesive and/or stitch bonding. of fusion. Melting point bonding can be selected from, but not limited to, ultrasonic bonding, pressure bonding, thermal bonding, and combinations thereof. In one application, melting point bonding can be provided in any standard deemed suitable.
[119] The acquisition layer 84 may have any longitudinal length dimension as deemed appropriate. The acquisition layer 84 can have a longitudinal length of about 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 225, 230, 240 or 250 mm to about 260, 270, 280, 290, 300, 310, 320, 340, 350, 360, 380, 400, 410, 415, 420, 425, 440, 450, 460, 480, 500, 510 or 520 mm. In one application, the acquisition layer 84 can be any length so that the acquisition layer 84 can be coincident with waist edges 22 and 24 of the absorbent article 10.
[120] In one application, the longitudinal length of the acquisition layer 84 may be the same as the longitudinal length of the absorbent body 40. In such an application, the midpoint of the longitudinal length of the acquisition layer 84 may substantially align with the midpoint of the longitudinal length of the absorbent body 40.
[121] In one application, the longitudinal length of the acquisition layer 84 may be less than the longitudinal length of the absorbent body 40. In such an application, the acquisition layer 84 may be positioned at any desired location along the longitudinal length of the absorbent body 40. As an example of such an application, the absorbent article 10 may contain a target area where repeated jets of liquid normally occur in the absorbent article 10. The specific location of a target area may vary depending on the age and gender of the user of the absorbent article 10. For example, male wearers tend to urinate more towards the front region of the absorbent article 10 and the target area may be gradually positioned forward within the absorbent article 10. For example, the target area for a male wearer it can be positioned approximately 2%" in front of the longitudinal midpoint of the absorbent body 40 and can have a length of about ± 3" and a width. that of about ± 2". The female target area may be located closest to the center of the genital region 16 of the absorbent article 10. For example, the target area for a female wearer may be positioned approximately 1" in front of the longitudinal midpoint of the absorbent body 40 and may have a length of about ± 3" and a width of about ± 2". As a result, the relative longitudinal positioning of the acquisition layer 84 within the absorbent article 10 can be selected to best match the target area of one or both categories of users.
[122] In one application, the absorbent article 10 may contain a centered target area within the genital region 16 of the absorbent article 10 with the premise that the absorbent article 10 will be worn by a female user. The acquisition layer 84, therefore, can be positioned along the longitudinal length of the absorbent article 10 so that the acquisition layer 84 can be substantially aligned with the target area of the absorbent article 10 intended for a female wearer. Alternatively, the absorbent article 10 may contain a target area positioned between the genital region 16 and the front waist region 12 of the absorbent article 10 with the premise that the absorbent article 10 will be worn by a male wearer. The acquisition layer 84, therefore, can be positioned along the longitudinal length of the absorbent article 10 so that the acquisition layer 84 can be substantially aligned with the target area of the absorbent article 10 intended for a male wearer.
[123] In one application, the acquisition layer 84 may have a size dimension that is the same size dimension as the target area of the absorbent article 10 or a size dimension greater than the size dimension of the target area of the absorbent article 10 In one application, the acquisition layer 84 may be in contact with and/or joined to the body facing material 28 at least partially in the target area of the absorbent article 10.
[124] In many applications, the acquisition layer 84 may have a longitudinal length that is less than, equal to or greater than the longitudinal length of the absorbent body 40. In an application where the absorbent article 10 is a diaper, the acquisition layer 84 may having a longitudinal length of about 120, 130, 140, 150, 160, 170 or 180 mm to about 200, 210, 220, 225, 240, 260, 280, 300, 310 or 320 mm. In such an application, acquisition layer 84 may be shorter in longitudinal length than the longitudinal length of absorbent body 40 and may be positioned progressively from the front end edge 46 of absorbent body 40 a distance of about 15, 20 or 25 mm to about 30, 35 or 40 mm. In an application where the absorbent article 10 may be training pants, or youth pants, the acquisition layer 84 may have a longitudinal length of about 120, 130, 140, 150, 200, 210, 220, 230, 240 or 250 mm to about 260, 270, 280, 290, 300, 340, 360, 400, 410, 420, 440, 450, 460, 480, 500, 510 or 520 mm. In such an application, the acquisition layer 84 may have a longitudinal length less than the longitudinal length of the absorbent body 40 and may be progressively positioned at a distance from about 25, 30, 35 or 40 mm to about 45, 50, 55, 60, 65, 70, 75, 80 or 85 mm from the front end edge 46 of the absorbent body 40. In an application where the absorbent article 10 is an adult incontinence garment, the acquisition layer 84 may have a length longitudinal from about 200, 210, 220, 230, 240, or 250 mm to about 260, 270, 280, 290, 300, 320, 340, 360, 380, 400, 410, 415, 425 or 450 mm. In such an application, the acquisition layer 84 may have a longitudinal length less than the longitudinal length of the absorbent body 40 and the acquisition layer 84 may be progressively positioned at a distance of about 20, 25, 30 or 35 mm to about 40, 45, 50, 55, 60, 65, 70 or 75 mm from the front end edge 46 of absorbent body 40.
[125] The acquisition layer 84 can have any width as desired. The acquisition layer 84 can have a width dimension of 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, or 70 mm up to about 80, 90, 100, 110, 115, 120, 130, 140, 150, 160, 170 or 180 mm. The width of the acquisition layer 84 can vary depending on the size and shape of the absorbent article 10 into which the acquisition layer 84 will be placed. The acquisition layer 84 may have a width less than, equal to, or greater than the width of the absorbent body 40. Within the genital region 16 of the absorbent article 10, the acquisition layer 84 may have a width less than, equal to, or greater than the width of the absorbent body 40.
[126] In one application, acquisition layer 84 may include natural fibers, synthetic fibers, superabsorbent material, woven material, non-woven material, wet deposited fibrous webs, a substantially unlimited air-deposited fibrous web, a deposited fibrous web by air, stabilized and operatively joined, or the like, as well as combinations thereof. In one application, acquisition layer 84 can be formed of a material that is substantially hydrophobic, such as a non-woven web composed of polypropylene, polyethylene, polyester, and the like, and combinations thereof.
[127] In many applications, acquisition layer 84 may have fibers that may have a thickness on the denier scale greater than about 5. In many applications, acquisition layer 84 may have fibers that may have a thickness on the scale. "denier" less than about 5.
[128] In one application, the acquisition layer 84 can be a carded web joined by air as an air joined carded web composite of 50 gsm containing a homogeneous blend of bicomponent polyethylene/polypropylene fibers of about 50% sheath/core having a fiber diameter of 3 denier and about bicomponent polyethylene/polypropylene fibers having about 50% sheath/core having a fiber diameter of 1.5 denier. An example of such a composite is a composite containing 50% ES FiberVisions 3 denier ESC-233 bicomponent fibers and approximately 50% ES FiberVisions 1.5 denier ESC-215 bicomponent fibers, or equivalent composites, available from ES FiberVisions Corp., Duluth, GA, USA.
[129] In one application, the acquisition layer 84 can be a carded web joined by air as a composite of carded web joined by air to 50 gsm containing a homogeneous mixture of about 50% rayon fibers having a diameter of 3 denier fiber and about 50% sheath/core bicomponent polyethylene/polypropylene fibers having a fiber diameter of 1.5 denier. An example of such a composite is a composite containing fibers about 50% Kelheim with thickness on the 3 Rayon Galaxy "denier" scale and about 50% ESC-215 bicomponent fibers such as 1.5 denier from ES FiberVisions, or composites equivalents, available from ES FiberVisions Corp., Duluth, GA, USA.
[130] In one application, the acquisition layer 84 can be a carded web air-bonded as a 50 gsm air-bonded web composite containing a homogeneous mixture of approximately 40% hollow polypropylene fibers having a diameter of 7" denier" fiber and about 60% of polyethylene/polypropylene sheathed/core bicomponent fibers containing a 17" denier" fiber diameter. An example of such a composite is a composite of about 40% ES FiberVisions 7-denier T-118 hollow polypropylene fibers and about 60% ES FiberVisions 17-denier Varde bicomponent fibers, or equivalent compounds , available from ES FiberVisions Corp. , GA, USA.
[131] In one application, acquisition layer 84 can be a carded web joined through air as a carded web composite air joined to 35 gsm containing a homogeneous mixture of about 35% bicomponent fibers with sheath/core of polyethylene/polypropylene having a fiber diameter of 6 "denier", about 35% of bicomponent fibers with sheath/core of polyethylene/polypropylene having a fiber diameter of 2 "denier" and about 30% of polyester fibers containing a 6" denier" fiber diameter. An example of such a compound is a compound containing about 35% Huvis 180-N (PE/PP 6D), about 35% Huvis N-215 (PE/PP 2d) and about 30% Huvis SD-10 6d PET, or equivalent compound, available from SamBo Company, Ltd, Korea.
[132] In one application, acquisition layer 84 may be a thermally bonded air-deposited fibrous web (eg Concert product code DT200.100.D0001) that is available from Glatfelter, a company with offices located in York , PA, United States of America.
[133] In one application, the acquisition layer 84 can include a co-formed material/foam. In one application, acquisition layer 84 can include a co-formed resilient material. As used herein, the term "co-formed" refers to a mixture of blown and molten fibers and absorbent fibers such as cellulosic fibers which can be formed by air formation of a blown and molten polymer material while air-suspended fibers are simultaneously blown. in the flow of fused and blown fibers. The coformed material can also include other materials, such as superabsorbent materials. Fused and blown fibers and absorbent fibers (and other optional materials) can be collected on a forming surface, as provided by a perforated belt. The forming surface can include a gas permeable material that has been placed over the forming surface. Coforming materials are further described in US Patent Nos. 5,508,102 and 5,350,624 to Goulart et al and 4,100,324 to Anderson and US Patent No. 2012/0053547 to Schroeder et al., which are incorporated herein in their entirety by reference thereto and to the extent that they do not conflict. As used herein, the term "resilient co-formed" refers to a resilient co-formed non-woven layer including a matrix of fused and blown fibers and an absorbent material, wherein the fused and blown fibers constitute from about 30% by weight up to about 99% by weight of the web and the absorbent material constitutes from about 1% by weight to about 70% by weight of the web, and further wherein the fused and blown fibers are formed from a thermoplastic composition containing fur. minus a propylene/α-olefin copolymer having a propylene content of about 60 mole% to about 99.5% mole and an α-olefin content of about 0.5% mole to about 40 mole %, wherein the copolymer still has a density of about 0.86 to about 0.90 grams per cubic centimeter and the composition has a melt index of about 120 to about 6000 grams per 10 minutes, determined at 230°C according to ASTM test method D1238-E, although practical considerations can reduce the high end of the flow rate range.
[134] The acquisition layer 84 may have additional parameters including basis weight and thickness. In one application, the basis weight of acquisition layer 84 can be at least about 10 gsm or 20 gsm. In one application, the basis weight of acquisition layer 84 can be from about 10, 20, 30, 40, 50 or 60 gsm to about 65, 70, 75, 80, 85, 90, 100, 110, 120, or 130 gsm. In one application, the basis weight of acquisition layer 84 can be less than about 130, 120, 110, 100, 90, 85, 80, 75, 70, 65, 50 or 60 gsm. In one application, acquisition layer 84 may have a thickness, measured at 0.05 psi (0.345kPa), of less than about 1.5 mm. In an application, such as when the absorbent article 10 may be a diaper, the acquisition layer 84 may have a thickness, measured at 0.05 psi (0.345kPa), of less than 1.5 mm, 1.25 or 1.0. In an application, such as where the absorbent article may be a feminine hygiene product, the acquisition layer 84 may have a thickness, measured at 0.2 psi (1.379kPa), of less than 1.5 mm, 1 .25 or 1.0. Body contact material:
[135] As illustrated in Figures 7 - 9, a material facing body 28 may be a fluid interwoven laminated web with projections 90 extending outwardly and away from at least one anticipated outer surface of the laminated web. In one application, the projections 90 may be hollow. The body facing material 28 can have two layers such as a backing layer 92 and a projection layer 94. The backing layer 92 can have a first surface 96 and an opposing second surface 98 as well as a thickness 100. projection 94 may have an inner surface 102 and an opposite outer surface 104 as well as a thickness 106. An interface 108 may be present between the backing layer 92 and the projection layer 94. In one application, fibers from the projection layer 94 may cross interface 108 and be interwoven with and wrap around backing layer 92 to form the body facing material 28. In an application where backing layer 92 is a fibrous web of non-woven fabric, the fibers of the body layer support 92 can cross interface 108 and be intertwined with fibers in projection layer 94. Body Facing Material Projections
[136] In one application, the projections 90 may be filled with fibers from the projection layer 94 and/or support layer 92. In one application, the projections 90 may be hollow. The projections 90 may have closed ends 110, which may be devoid of openings. In some applications, however, it may be desirable to increase the pressure and/or collision residence time of the liquid jets in the weaving process as described herein to create one or more openings (not shown) in each of the projections 90. Apertures may also be formed in the body facing material through forming posts (not shown) which may be located on the projection forming surface 156 (such as forming surface 156 in Figures 12 and 12A). Such openings may be formed in the closed ends 110 and/or sidewalls 112 of the projections 90. Such openings are to be distinguished from the fiber-to-fiber interstitial spacing which is the spacing of one single fiber to the next single fiber.
[137] In many applications, the projections 90 may have a percentage of open area where light can pass through the projections 90 unhindered by the material forming the projections 90, such as fibrous material. The percentage of open area present in projections 90 involves the entire area of projection 90 where light can pass through projection 90 without hindrance. Thus, for example, the percentage of open area of a projection 90 may encompass the entire open area of projection 90 through apertures, fiber-to-fiber interstitial spacing and any other spacing within projection 90 where light can pass unhindered. In one application, the projections 90 may be formed without openings and the open area may be due to fiber-to-fiber interstitial spacing. In various applications, projections 90 may be less than about 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2 or 0.1 % open area in a chosen area of material facing the body 28 as measured in accordance with the test method "Method for Determining Percent Open Area" described here in this document.
[138] In an application such as the non-limiting application illustrated in Figure 10, the projections 90 may be round when viewed from above with slightly domed or curved tops or closed ends 110, as seen when viewed in a cross-section such as shown in Figure 10A and 10B. The actual shape of the projections 90 can be varied depending on the shape of the forming surface into which the fibers of the projection layer 94 are forced. Thus, while not limiting the variations, the shapes of the projections 90 can be, for example, round, oval, square, rectangular, triangular, diamond-shaped, etc. The width and height of the projections 90 can be varied, as can the spacing and pattern of the projections 90. In one application, various shapes, sizes, and spacing of the projections 90 can be used on the same projection layer 94. In one application , the projections 90 may have a height, measured in accordance with the "Method for Determining Percent Open Area" test method described here, of more than about 1 mm. In one application, the projections 90 may have a height greater than about 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 mm. In one application, the projections 90 can have a height from about 1, 2, 3, 4 or 5 mm to about 6, 7, 8, 9, or 10 mm.
[139] The projections 90 of the material facing the body 28 may be located and emanate from the outer surface 104 of the projection layer 94. In one application, the projections 90 may extend from the outer surface 104 of the projection layer 94 at one direction away from the backing layer 92. In an application where the projections 90 may be hollow, they may have open ends 114 which may be located towards the inner surface 102 of the projection layer 94 and may be covered by the second surface 98 of backing layer 92 or inner surface 102 of projection layer 94 depending on the amount of fiber that has been used from projection layer 94 to form projections 90. Projections 90 may be surrounded by deposit areas 116 which may be formed from the outer surface 104 of the projection layer 94 although the thickness of the deposit areas 116 can be comprised of both the projection layer 94 and the backing layer 92. Deposit 116 may be relatively flat, as shown in Figures 7 and 8, or topographical variability may be built into the deposit areas 116. For example, in one application, a deposit area 116 may have a plurality of three-dimensional shapes formed therein. forming the projection layer 94 into a three-dimensionally formed forming surface as disclosed in U.S. Patent No. 4,741,941 to Engelbert et al assigned to Kimberly-Clark Worldwide and incorporated herein by reference in its entirety for all purposes. For example, in one application, a deposition area 116 may be provided with depressions 118 which can extend fully or partially into the projection layer 94 and/or backing layer 92. In addition, a deposition area 116 can be embossed that can impart surface texture and other functional attributes to the deposit area 116. In one application, a deposit area 116 and the material facing the body 28 as a whole may be provided with openings 120 that can extend through the body-facing material 28 to further facilitate the movement of fluids (such as the liquids and solids that make up bodily secretion) into and through the body-facing material 28. Such openings 120 should be distinguished from fiber-to-fiber interstitial spacing, which is the spacing from one single fiber to the next single fiber.
[140] In various applications, the deposit areas 116 may have a percentage of open area where light can pass through the deposit areas 116 unhindered by the material that forms the deposit areas 116, such as fiber material. The percentage of open area present in the deposit areas 116 encompasses the entire area of the deposit areas 116 where light can pass through the deposit areas 116 without hindrance. Thus, for example, the percentage of open area of a deposit area 116 may encompass the entire open area of the deposit areas 116 through openings, fiber-to-fiber interstitial spacing and any other spacing within the deposit areas 116 where light can pass without obstacles. In various applications, deposit areas 116 may have an open area greater than about 1% in a chosen area of material facing the body 28, as measured in accordance with the test method "Method for Determining Percent Open Area " described in this document. In one application, the deposit areas 116 may be formed without openings and the open area may be due to fiber-to-fiber interstitial spacing. In various applications, the deposit areas 116 can have an open area greater than about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20% on a chosen area of material facing the body 28. In many applications, the deposit areas 116 may have an open area greater than about 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5 or 20% in a chosen area of material facing the body 28. In various applications, deposit areas 116 can be from about 1, 2 or 3% up to about 4 or 5% open area in a chosen area of the body facing material. In various applications, the deposit areas 116 may have from about 5, 6, or 7% to about 8, 9 or 10% open area in a chosen area of material facing the body 28. In various applications, the areas of deposit 116 may have from about 10, 11, 12, 13, 14 or 15% to about 16, 17, 18, 19 or 20% open area in a selected area of material facing the body 28. In applications, the deposit areas 116 may have an open area greater than about 20% in a chosen area of material facing the body 28.
[141] Projections 90 of material facing body 28 may be provided in any orientation as deemed appropriate. In one application, the projections 90 of the body facing material 28 may be randomly supplied to the body facing material 28. In one application, the projections 90 may be linearly oriented in the longitudinal direction 30 of the absorbent article 10. In one application, the projections 90 may be linearly oriented in the lateral direction 32 of the absorbent article 10. In one application, the projections 90 may be linearly oriented in a direction which may be at an angle to the longitudinal direction 30 and/or the lateral direction 32 of the article. absorbent 10. The deposition areas 116 of material facing the body 28 may be provided in any orientation as deemed appropriate. In one application, the depot areas 116 may be linearly oriented in the longitudinal direction 30 of the absorbent article 10. In one application, the depot areas 116 may be linearly oriented in the lateral direction 32 of the absorbent article 10. In one application, the areas depot 116 may be linearly oriented in a direction which may be at an angle to the longitudinal direction 30 and/or the lateral direction 32 of the absorbent article 10.
[142] In one application, the projections 90 and/or the deposition areas 116 may be provided such that the projections 90 are located in the genital region 16 of the absorbent article 10, are situated towards the perimeter of the absorbent article 10 and their combinations. In one application, the projections 90 may have different heights in different areas of the absorbent article 10. In such an application, for example, the projections 90 may have a first height in one area of the absorbent article 10 and a different height in an area other than the one. In one application, the projections 90 may have varying diameters in different areas of the absorbent article 10. In such an application, for example, the projections 90 may have a first diameter in one area of the absorbent article 10 and may have a diameter different in another area of the absorbent article 10. In one application, the concentration of projections 90 may vary in the absorbent article 10. In such an application, an area of the absorbent article 10 may have a greater concentration of projections 90 than the concentration of projections 90 in a second area of the absorbent article 10.
[143] In one application, the projections 90 and/or the deposit areas 116 may be provided in a standardized orientation. Non-limiting examples of standard orientations may include, but are not limited to, lines, circles, squares, rectangles, triangles, ovals, stars, and hexagons. In one application, a patterned orientation can be provided so that the patterned orientation is parallel to the longitudinal direction 30 and/or the lateral direction 32 of the absorbent article 10. In one application, a patterned orientation can be provided so that the patterned orientation is at an angle to the longitudinal direction 30 and/or the lateral direction 32 of the absorbent article 10. In one application, a projection 90 of the material facing the body 28 may be at least partially aligned, fully aligned, or completely non-aligned with another. projection 90 of the material facing the body 28, such as an adjacent projection 90. Without being bound by theory, it is believed that the alignment (either a partial alignment, or not full lineage) of a projection 90 of the material facing the body 28 with another projection 90, such as an adjacent projection 90, of the material facing the body 28 may result in deposit area channels 116 which may further impede the further spreading of bodily secretions along the body facing material 28 of the absorbent article 10 and/or may direct the spreading of bodily secretions toward desired locations of the body facing material 28 of the absorbent article 10.
[144] As illustrative examples, Figures 11A, 11B, and 11C provide illustrations of an exemplary application of partial alignment, complete alignment, and complete misalignment of two projections on adjacent projection lines. In the application illustrated, for example, in Figure 11A, a first row 91 of projections 90 may be disposed linearly in a direction that is parallel with the longitudinal direction 30 of the absorbent article 10. In such an application, a projection 90 of a first row 91 of projections 90 that are oriented parallel to the machine direction 30 of the absorbent article may be at least partially aligned with a projection 90 of a second line immediately adjacent 93 of the projections 90 that are oriented in a direction parallel to the machine direction 30 of the absorbent article. In such an application, a partial alignment of a projection 90 of a first line 91 of the projections 90 which are oriented in a direction parallel to the longitudinal direction 30 of the absorbent article 10 with a projection 90 of an immediately adjacent second line 93 of the projections 90 which is oriented in a direction parallel to the longitudinal direction 30 of the absorbent article 10 may result in passing an imaginary line 95 in the lateral direction 32 of the absorbent article 10 through each of the projections 90 of the first 91 and second 93 lines of the projections 90. It will be understood that the passage of the imaginary line 95 through each of the projections 90 of the first 91 and second 93 lines of projections 90 does not necessarily result in a passage through the midpoint of each of the projections 90 of the first 91 and second 93 lines of projections 90. In the application illustrated, for example, in Figure 11B, a first row 91 of projections 90 may be linearly disposed in a direction that is parallel. it with the longitudinal direction 30 of the absorbent article 10. In such an application, a projection 90 of a first row 91 of projections 90 which are oriented in a direction parallel to the longitudinal direction 30 of the absorbent article 10 may be completely aligned with a projection 90 of a second line 93 immediately adjacent to the projections 90 that are oriented parallel with a longitudinal direction 30 of the absorbent article 10. In such an application, a complete alignment of a projection 90 of a first line 91 of projections 90 that are oriented in a parallel direction to the longitudinal direction 30 of the absorbent article 10 with a projection 90 of a second line immediately adjacent 93 of the projections 90 which is oriented parallel to a longitudinal direction 30 of the absorbent article 10 may result in passing an imaginary line 95 in the lateral direction 32 of the absorbent article 10 through each of the projections 90 of the first 91 and second 93 lines of projections 90. In this case, the imaginary line 95 may pass through the midpoint of each of the projections 90 of the first 91 and second 93 lines of projections 90. In the application illustrated, for example, in Figure 11C, a first line 91 of projections 90 may be disposed. linearly in a direction that is parallel to the longitudinal direction 30 of the absorbent article 10. In such an application, a projection 90 of a first row 91 of projections 90 that are oriented in a direction parallel to the longitudinal direction 30 of the absorbent article 10 may be completely not aligned with a projection 90 of a second line 93 immediately adjacent to projections 90 that are oriented in a direction parallel to the longitudinal direction 30 of the absorbent article 10. In such an application, a complete non-alignment of a projection of 90 of a first line 91 of projections 90 that are oriented in a direction parallel to the longitudinal direction 30 of the absorbent article 10 with a projection 90 of a second line 93 immediately adjacent to the and projections 90 that are oriented in a direction parallel to the longitudinal direction 30 of the absorbent article 10 may result in an imaginary line 95 passing in the lateral direction 32 of the absorbent article 10 through only one of the projections 90 or through none of the projections 90 of the absorbent article 10. first line 91 and second line 93 of projections 90. It should be understood that additional configurations of partial alignment, complete alignment and complete non-alignment may be formed.
[145] Although it is possible to vary the density and fiber content of the 90 projections, in an application, the 90 projections can be "hollow". Referring to Figures 10A and 10B, it can be seen that when the projections 90 are hollow, they may have a casing 122 formed from the fibers of the projection layer 94. The casing 122 may define an internal space 124 which may have a lower fiber density compared to casing 122 of projections 90. By "density" is meant the fiber count or content per chosen unit of volume within a portion of the interior space 124 or casing 122 of projection 90. The distance 103 between the outer shell surface of the shell 122 and the inner shell surface of the shell 122, as well as the density of the shell 122 may vary within a particular or individual projection 90 and this may also vary between different projections 90. In addition, the size of the hollow interior 124 as well as its density may vary within a particular or individual projection 90 and may also vary between different projections 90. The photomicrographs of Figures s 10A and 10B show a lower density or fiber count in the interior space 124 compared to housing 122 of the illustrated projection 90. As a result, if there is at least a portion of an interior space 124 of a projection 90 that has a density of fiber smaller than at least a portion of the casing 122 of the same projection 90, then the projection is considered to be "hollow". In this regard, in some situations, there may not be a well-defined demarcation between the casing 122 and the interior 124, but with sufficient enlargement of a section of one of the projections, it can be seen that at least some portion of the interior space 124 of the projection 90 has a lower density than a portion of housing 122 of the same projection 90, so projection 90 is considered to be "hollow". Furthermore, if at least a portion of the projections 90 of a material facing the body 28 are hollow, the projection layer 94 and the material facing the body 28 are considered to be "hollow", or containing "hollow projections". In one application, the portion of the projections 90 that are hollow may be greater than or equal to about 50% of the projections 90 in a chosen area of material facing the body 28. In one application, more than or equal to about 70 per One hundred of the projections 90 in a chosen area of the material facing the body 28 may be hollow. In one application, more than or equal to about 90 percent of the projections 90 in a selected area of material facing the body 28 may be hollow.
[146] As will become more apparent in connection with the description of processes defined below, the material facing the body 28 may be the result of movement of fibers in projection layer 94 in one and sometimes two or more directions. Referring to Figure 9, if the forming surface (such as forming surface 156 in Figures 12 and 12A) on which the projection layer 94 is placed is solid, except for the forming holes (for example, the forming holes 170 in Figure 12A) used to form the projections 90, then the impact force of the fluid jets that interweave and bounce off the solid surface deposit areas (such as the deposit areas 172 in Figure 12A) corresponding to the deposit areas 116 of the projection layer 94 can lead to a migration of fibers adjacent from the inner surface 102 of the projection layer 94 into the support layer 92 adjacent to its second surface 98. This migration of fibers in the first direction can be represented by the arrows 126 shown in Figure 9. In order to form the projections 90 that extend outwardly from the outer surface 104 of the projection layer 94, there must be a migration of fibers in a second direction as indicated by the arrows. 128. It is this migration in the second direction that causes the fibers of the projection layer 94 to move outward and away from the outer surface 104 to form the projections 90.
[147] In an application where the backing layer 92 may be a fibrous non-woven web, depending on the degree of integrity of the web and the strength and residence time of the fluid jets, there may also be movement of the fibers in the backing layer 92 into projection layer 94 as indicated by arrows 130 in Figure 9. The end result of these fiber movements can be the creation of a body facing material 28 with good overall integrity and lamination of the layers (92 and 94) at its interface 108 thus allowing further processing and handling of material facing the body 28. As a result of the fluid entanglement processes described herein, it is generally not desirable that the fluid pressure used to form the projections 90 be of sufficient strength. so as to force the fibers of the backing layer 92 to be exposed on the outer surface 104 of the projection layer 94. Support Layer and Projection Layer of the Body Facing Material
[148] As the name implies, support layer 92 can support projection layer 94 containing projections 90 and can be made of a number of structures, provided support layer 92 may be able to support projection layer 94. The main functions of the support layer 92 may be to protect the projection layer 94 during the formation of the projections 90, to be able to join or be intertwined with the projection layer 94 and to further assist the processing of the projection layer 94 and the resulting body facing material 28. Suitable materials for backing layer 92 may include, but are not limited to, non-woven fabrics or wefts, open weft materials, paper/cellulose/cellulose pulp based products that may be considered a subset of non-woven mesh or wefts as well as foam materials, films and combinations of the above, provided that the material or materials chosen are capable of supporting a manufacturing process as a product. fluid weaving process. In one application, backing layer 92 may be a non-woven fibrous web made from a plurality of randomly deposited fibers which may be natural fibers as are used, for example, in carded webs, air laid webs, etc. or they can be more continuous fibers as found in, for example, cast and blown or spin-bonded webs. Due to the functions that backing layer 92 must perform, backing layer 92 can have a higher degree of integrity than projection layer 94. to the fluid entanglement process discussed in more detail below. The degree of integrity of the backing layer 92 can be such that the material forming the backing layer 92 can resist being pushed down into and filling the projections 90 of the projection layer 94. As a result, in an application where backing layer 92 is a fibrous non-woven web, this should have a higher degree of fiber-to-fiber bonding and/or fiber entanglement than the fibers in projection layer 94. Although it may be desirable to have fibers of the support layer 92 interlaced with the fibers of projection layer 94 adjacent the interface 108 between the two layers, it is generally desired that the fibers of this support layer 92 are not integrated or intertwined with projection layer 94 to such an extent that large portions thereof fibers find their way into the 90 projections.
[149] In one application, a function of backing layer 92 may be to facilitate further processing of projection layer 94. In one application, the fibers used to form projection layer 94 may be more expensive than those used to form the backing layer 92. As a result, in such an application, it may be desirable to keep the basis weight of the projection layer 94 low. In doing so, however, it can become difficult to process projection layer 94 after it has been formed. After affixing the projection layer 94 to an underlying support layer 92, processing, winding and unwinding, storing and other activities can be done more efficiently.
[150] In order to withstand the higher degree of fiber movement, as mentioned above, in an application, backing layer 92 may have a higher degree of integrity than projection layer 94. This higher degree of integrity it can be caused in several ways. One way can be fiber-to-fiber bonding, which can be achieved by thermally or ultrasonic bonding the fibers together with or without the use of pressure such as air bonding, point bonding, powder bonding, chemical bonding, bonding by adhesive, stamping, calender joining, etc. Furthermore, other materials can be added to the fibrous mixture such as adhesives and/or bicomponent fibers. Pre-interlacing a fibrous non-woven fabric backing layer 92 can also be used, such as by subjecting the weft to hydroentangling, needle punching, etc., before this backing layer 92 is joined to a projection layer 94. Combinations of the above are also possible. Still other materials such as foams, open-woven cotton and nets may have sufficient initial integrity so that they do not need further processing. The level of integrity can in many cases be visually observed due to, for example, observation with the naked eye of such techniques as stitch bonding which is commonly used with fibrous non-woven webs such as spunbonded webs and webs containing spunbond fiber. standard length. Further enlargement of the backing layer 92 may also reveal the use of fluid entanglement or the use of thermal and/or adhesive bonding to join the fibers together. Depending on whether individual layer samples (92 and 94) are available, tensile testing in one or both machine and cross directions can be performed to compare the integrity of support layer 92 to projection layer 94. See for example test ASTM D5035-11, which is incorporated herein in its entirety for all intents and purposes.
[151] The type, basis weight, tensile strength, and other properties of the backing layer 92 can be chosen and varied depending on the particular end use of the resulting body-facing material 28. When the body-facing material 28 is to be Used as part of an absorbent article such as an absorbent personal care article, cleaning wipe, etc., it may generally be desirable for the backing layer 92 to be a layer that is fluid permeable, has good wet and dry resistance, is capable. of absorbing fluids such as bodily secretions, possibly retaining the fluids for a period of time and then releasing the fluids to one or more underlying layers. In this regard, fibrous nonwovens such as spin joined webs, blown and cast webs and carded webs such as air deposited webs, joined carded webs and coformed materials are well suited as backing layers 92. Foam materials and cotton weft materials open are also well suited. In addition, backing layer 92 can be a multi-layer material due to the use of multiple layers or the use of ATM-forming processes as are commonly used in the fabrication of spin-bonded webs and blown and cast webs, as well as layer combinations. of cast and blown wefts and joined by spinning. In forming such backing layers 92, natural as well as synthetic materials can be used alone or in combination to make the materials. In various applications, backing layer 92 can have a basis weight ranging from about 5 to about 40 or 50 gsm.
[152] The type, basis weight, and porosity of support layer 92 can affect the process conditions necessary to form projections 90 on projection layer 94. Heavier basis weight materials can increase the interweaving force of fluid flows from braiding required to form projections 90 on projection layer 94. However, heavier basis weight support layers 92 may also provide improved support for projection layer 94 as it has been determined that projection layer 94 itself is very elastic. to keep the shape of the 90 projections after the training process. The projection layer 94 by itself can unduly elongate in the machine direction due to mechanical forces exerted on it by the subsequent winding and converting processes and consequently decrease and distort the projections. Furthermore, without the backing layer 92, the projections 90 on the projection layer 94 tend to collapse due to winding pressures and compressive weights that the projection layer 94 experiences in the process of winding and subsequent conversion and does not recover in the as it occurs when a support layer 94 is present.
[153] Backing layer 92 can be subjected to additional treatment and/or additives to change or improve its properties. For example, surfactants and other chemicals can be added either internally or externally to components that form all or a portion of backing layer 92 to alter or improve its properties. Compounds commonly referred to as hydrogels or superabsorbents that absorb many times their weight in liquids can be added to the backing layer 92 in the form of particles and fibers.
[154] The projection layer 94 can be made of a plurality of randomly deposited fibers which can be natural fibers as are used, for example, in carded webs, air deposited webs, co-formed webs, etc., or they can be more continuous fibers as are found in, for example, cast and blown or spin-bonded webs. The fibers in projection layer 94 may have less fiber-to-fiber bonding and/or fiber intertwining and therefore less integrity compared to the integrity of backing layer 92, especially in applications where backing layer 92 is a web. of fibrous non-tissue. In one application, the fibers in projection layer 94 may have no initial fiber-to-fiber bonding for purposes of allowing the formation of projections 90 as will be explained in more detail below in connection with the description of one or more of the applications of the method and apparatus for forming the body facing material 28. Alternatively, when both the backing layer 92 and the projection layer 94 may both be fibrous non-woven webs, the projection layer 94 may have less integrity than the layer. of backing 92 because layer 94 has, for example, less fiber-to-fiber bonding, less adhesive, or less pre-entanglement of the fibers that form projection layer 94.
[155] Projection layer 94 may have a sufficient amount of fiber movement capability to allow the below-described fluid interlacing process to be able to move a first plurality of the plurality of fibers from projection layer 94 outward in the XY plane of the projection layer 94 and perpendicular or in the Z direction of the projection layer 94 in order to form the projections 90 (illustrated in Figure 7). As noted herein in this document, in various applications the projections 90 may be hollow. As described herein in this document, in one application, a second plurality of fibers in projection layer 94 may become interwoven with backing layer 92. If more continuous fiber structures are being used as blown and cast webs or joined webs by spinning, in one application, there may be little or no pre-adhesion of projection layer 94 prior to the fluid weaving process. Longer fibers such as those generated in blown and melt-bonded processes (which are often referred to as continuous fibers to differentiate them from natural fibers) will typically require more force to move the fibers in the Z direction than shorter natural fibers , which typically have fiber lengths of less than about 100mm and more typically fiber lengths in the range of 10 to 60mm. Conversely, standard length fiber webs such as carded webs and air deposited webs may have some degree of pre-adhesion or interweaving of the fibers due to their shorter length. Such shorter fibers require less fluid force from the fluid entanglement flows to move them in the Z direction to form the projections 90. As a result, a balance between fiber length, degree of fiber pre-adhesion, must be satisfied, fluid strength, web velocity and dwell time in order to be able to create the projections 90 without, unless desired, forming openings in the deposit areas 116 or the projections 90 or forcing too much material into the interior space 124 of the projections 90, thus making the projections 90 too rigid for some end-use applications.
[156] In various applications, projection layer 94 can have a basis weight ranging from about 10 gsm to about 60 gsm. Spin-bonded webs can typically have basis weights of between about 15 and about 50 gsm when being used as projection layer 94. Fiber diameters can range between about 5 and about 20 microns. The fibers can be single-component fibers formed from a single polymer composition or they can be bi-component or multi-component fibers in which a portion of the fiber can have a lower melting point than the other components to allow for bonding. fiber-to-fiber with the use of heat and/or pressure. Hollow fibers can also be used. Fibers can be formed from any polymer formulations commonly used to form spunbonded webs. Examples of such polymers include, but are not limited to, polypropylene ("PP"), polyester ("PET"), polyamide ("PA"), polyethylene ("PE") and polylactic acid ("PLA"). Spin-bonded webs can be subjected to post-form bonding and weaving techniques if necessary to improve the processability of the web before being subjected to the projection forming process.
[157] Cast and blown webs can typically have basis weights of between about 20 and about 50 gsm when being used as projection layer 94. Fiber diameters can range between about 0.5 and about 5 microns. The fibers can be single-component fibers formed from a single polymer composition or they can be bi-component or multi-component fibers in which a portion of the fiber can have a lower melting point than the other components to allow for bonding. fiber-to-fiber with the use of heat and/or pressure. Fibers can be formed from any polymer formulations commonly used to form spunbonded webs. Examples of such polymers include, but are not limited to, PP, PET, PA, PE and PLA.
[158] Air-deposited and carded wefts can use natural fibers that typically can range in length from about 10 to about 100 millimeters. The thickness on the "denier" scale of the fiber can range from about 0.5 to 6 denier, depending on the particular end use. Basis weights can range from about 20 to about 60 gsm. Natural fibers can be made from a wide variety of polymers, including, but not limited to, PP, PET, PA, PE, PLA, cotton, rayon, linen, wool, hemp, and regenerated cellulose such as Viscose . Fiber blends can also be used as blends of bicomponent fibers and single component fibers as well as blends of solid fibers and hollow fibers. If bonding is desired, this can be accomplished in a number of ways, including, for example, through air bonding, calender bonding, spot bonding, chemical bonding and adhesive bonding such as powder bonding. If necessary, to further increase the integrity and processability of a projection layer 94 prior to the projection formation process, the projection layer 94 can be subjected to pre-interlacing processes to increase fiber interlacing within the layer. projection 94 before the formation of projections 90. Hydroentanglement can be advantageous for this aspect.
[159] Although the aforementioned non-woven weft types and forming processes are suitable for use in conjunction with projection layer 94, it is anticipated that other wefts and forming processes may also be used as long as the wefts are capable of form the projections 90.
[160] Support layer 92 and projection layer 94 can be made in a variety of basis weights depending on the particular end application. For example, body facing material 28 can have a total basis weight of about 15, 20 or 25 to about 100, 110 or 120 gsm and backing layer 92 can have a basis weight of about 5 to about of 40 or 50 gsm while projection layer 94 can have a basis weight of about 15 or 20 to about 50 or 60 gsm. Such basis weight ranges may be possible due to the way in which the material facing the body 28 can be formed and the use of two different layers with different functions in relation to the forming process. As a result, the body facing material 28 can be made in commercial environments that were hitherto not considered possible due to the inability to process the individual wefts and form the desired projections 90.
[161] In one application, the body-facing material 28 of an absorbent article 10 can have a load of more than about 2 Newtons per 25 mm wide at a 10% machine direction span. In one application, the body-facing material 28 of an absorbent article 10 may have a load of more than about 4 Newtons per 25 mm wide over a 10% machine direction span. In one application, the body-facing material 28 of an absorbent article 10 can have a load of more than about 6 Newtons per 25mm wide over a 10% machine direction span. In various applications, the body facing material 28 of an absorbent article 10 can have a resiliency greater than about 70%. In various applications, the body facing material 28 of an absorbent article 10 can have a resiliency greater than about 70, 73, 75, 77, 80 or 83%.
[162] In various applications, the absorbent article 10 can be a diaper. In various applications, the amount of residual fecal material simulator in the material facing the body 28 of an absorbent article 10 after etching with fecal material simulator as measured according to the test method for the "Determination of Residual Fecal Material Simulator " described herein may be less than about 2.5, 2.4, 2.3, 2.2, 2.1, 2.0, 1.9, 1.8, 1.7, 1.6 or 1.5 grams. In various applications, the spread area of the fecal material simulator on the material facing the body 28 of an absorbent article 10 after etching with a fecal material simulator as measured in accordance with the test method for the "Spread Area Determination of Fecal Material Simulator" described in this document may be less than about 34, 33, 32, 31, 30 or 29 cm2.
[163] In many applications, the absorbent article 10 can be a feminine hygiene product. In various applications, the second time of entry through a body facing material 28 into an absorbent article 10 after attack with a menstruation simulator may be less than about 30, 20 or 15 seconds measured using the Entry test method /Rewetting described here in this document. In various applications, the second entry time of the menstruation simulator through a body facing material 28 into an absorbent article 10 can be from about 25 or 30% to about 50, 60 or 70% less than the commercially available product. available after attack with the menstruation simulator as measured using the Entry/Rewet test method described here in this document. In various applications, the second entry time through a body facing material 28 into an absorbent article 10 can be about 25, 30, 31, 47, 49, 50, 54, 60, 64, 66 or 70% less than than commercially available post-attack products with a menstruation simulator as measured using the Entry/Rewet test method described herein.
[164] In various applications, the second time of entry through a body-facing material 28 into an absorbent article 10 after attack with a menstruation simulator may be less than about 30, 20, or 15 seconds, without an increase in amount of rewet as measured using the Inlet/Rewet test method described herein. In various applications, the second entry time of the menstruation simulator through a body facing material 28 into an absorbent article 10 can be from about 25 or 30% to about 50, 60 or 70% less than the commercially available product. available without an increase in the amount of soaking after attack with the menstruation simulator, as measured using the Entry/Soak test method described here in this document. In various applications, the second entry time through body facing material 28 into an absorbent article 10 after menstruation simulator attack may be about 25, 30, 31, 47, 49, 50, 54, 60, 64 , 66 or 70% less than commercially available products without an increase in rewetting amount. Process for Fabricating Body Facing Material
[165] A fluid braiding process can be employed to form the material facing the body 28. Any number of fluids can be used to join the support layer 92 and projection layer 94 together including liquids and gases. The most common technology used in this regard may be referred to as spinning braided or hydroentangled technology, which can use pressurized water as the braiding fluid.
[166] Referring to Figure 12 there is shown an application of a method and apparatus for forming a fluid-entangled body facing material 28 with projections 90. Apparatus 150 may include a first conveyor belt 152, a drive roller of the conveyor belt 154, a projection forming surface 156, a fluid entanglement device 158, an optional overfeed roller 160, and a fluid removal system 162 such as a vacuum suction device or other conventional device. Such vacuum devices and other means are well known to those of skill in the art. Conveyor belt 152 can convey projection layer 94 in apparatus 150. If any pre-entanglement is done on projection layer 94 upstream of the process illustrated in Figure 12, conveyor belt 152 may be porous. The conveyor belt 152 can travel in a first direction (which is the machine direction), as indicated by arrow 164 at a first speed or V1 speed. The conveyor belt 152 may be driven by a conveyor belt drive roller 154 or other suitable means, as are known to those skilled in the art.
[167] The projection forming surface 156 as shown in Figure 12 may be in the form of a texturing drum and a partially exploded view of the surface is shown in Figure 12A. Projection forming surface 156 may move in the machine direction as shown by arrow 166 at a speed or velocity V3. It can be driven and its speed controlled by any suitable drive means (not shown) such as electric motors and gears, as are known to those of skill in the art. The projection forming surface 156 shown in Figures 12 and 12A may have a forming surface 168 containing a pattern of forming holes 170 which may correspond to the shape and pattern of the desired projections 90 in the projection layer 94 and the forming holes 170 may be separated by a deposit area 172. Forming holes 170 can be any shape and any pattern. As can be seen from the Figures depicting the material facing the body 28, the shapes of the forming hole 170 may be round, but it should be understood that any number of shapes and combination of shapes may be used depending on the end use application. . Examples of possible shapes of forming hole 170 include, but are not limited to, ovals, crosses, squares, rectangles, diamond shapes, hexagons, and other polygons. Such shapes can be formed on the projection forming surface 156 by melting, punching, stamping, laser cutting and water jetting. The spacing of the forming holes 170 and therefore the degree of deposit area 172 may also be varied depending on the particular final application of the material facing the body 28. In addition, the pattern of the forming holes 170 in the projection forming surface 156 may be varied depending on the particular final application of the material facing the body 28.
[168] The material forming the projection-forming surface 156 can be any number of suitable materials commonly used for forming such surfaces including, but not limited to, sheet metal, plastics and other polymer materials, rubber, etc. . Forming holes 170 can be formed in a sheet of material which is then formed into a projection forming surface 156 or the projection forming surface 156 can be molded or cast from suitable materials or printed with 3D printing technology. Projection forming surface 156 may be detachably mounted to and over an optional porous inner drum housing 174 so that different forming surfaces 168 can be used for different end product designs. Porous inner drum housing 174 may interact with fluid removal system 162 which may facilitate pulling the intertwining fluid and fibers down into forming holes 170 in outer forming surface 168 thereby forming projections 90 in the layer of projection 94. The porous inner drum housing 174 may also act as a barrier to further retard fiber movement downward to the fluid removal system 162 and other portions of the equipment, thereby reducing equipment fouling. The porous inner drum housing 174 can rotate in the same direction and at the same speed as the projection forming surface 156. In addition, to further control the height of the projections 90, the distance between the inner drum housing 174 and the forming surface projection 156 can be varied. In an application where a porous inner drum casing is used, the distance between the outer casing surface of the inner drum casing 174 and the inner casing surface of the projection-forming surface 156 can range from about 0 to about 5 mm.
[169] The cross-sectional dimensions of the forming holes 170 and their depth may influence the cross section and height of the projections 90 produced in the projection layer 94. In one application, the depth of the forming hole 170 in the projection forming surface 156 may correspond to projection height 90. In one application, the depth of the forming holes 170 in the projection forming surface 156 can be from about 1 or 3 mm to about 5 or 10 mm. In one application, a cross-sectional size of forming hole 170 may be from about 2 or 3 mm to about 6 or 10 mm as measured along the main axis. In one application, a spacing from forming hole 170 on a center-to-center basis can be from about 3 or 4 mm to about 7 or 10 mm. The pattern of spacing between the forming holes 170 can be varied and selected depending on the particular end use. Some examples of patterns include, but are not limited to, aligned patterns of rows and/or columns, skewed patterns, hexagonal patterns, wavy patterns, and patterns representing images, figures and objects. It should be noted that the depth, spacing, size, shape and other parameters of the forming holes 170 can be varied independently of one another and can be varied based on the particular end use of the material facing the body 28 being formed.
[170] The deposit areas 172 on the forming surface 168 of the projection forming surface 156 may be solid so as not to pass the interlacing fluid 176 emanating from the interlacing devices by fluid 158, but in some cases it may be desirable to make the liquid permeable deposit areas 172 to further texturize the exposed surface of projection layer 94. Alternatively, selected areas of forming surface 168 of projection forming surface 156 may be permeable to fluid and other impermeable areas. For example, a central region (not shown) of a projection forming surface 156 may be fluid permeable, while lateral regions (not shown) on either side of the central region may be fluid impermeable. In addition, deposit areas 172 on forming surface 168 may have enlarged areas (not shown) formed in or attached thereto to form optional depressions 118 and/or optional openings 120 in projection layer 94 and the material facing body 28 .
[171] In the application of the apparatus 150 shown in Figure 12, the projection forming surface 156 is shown in the form of a texturing drum. It should be noted however that other means may be used to create the projection forming surface 156. For example, a perforated strap or wire (not shown) may be used which includes forming holes 170 formed in the belt or wire at suitable locations. Alternatively, flexible rubberized straps that are impervious to weave flows by pressurized fluid, except for the forming holes 170, can be used. Such straps and yarns are well known to those skilled in the art as are the means to drive and control the speed of such straps and yarns. In one application, a texturing drum may be more advantageous for forming a body facing material 28 as described herein in this document because it can be made with deposit areas 172, which may be smooth and impervious to weaving fluid. 176 and which does not leave a yarn weft pattern on the outer surface 104 of projection layer 94 as yarn straps tend to do.
[172] An alternative to a projection forming surface 156 with a forming hole depth that defines the projection height may be a drum casing that is thinner than the desired projection height, but which can be spaced away from the projection. surface of the porous inner drum 174 over which it is wrapped. The spacing can be achieved by any means that preferably does not otherwise interfere with the process of forming the projections 90 and withdrawing the interlocking fluid from the equipment. For example, one medium may be a rigid wire or filament that can be inserted between projection forming surface 156 and porous inner drum 174 as a spacer or wrapped around porous inner drum 174 below projection forming surface 156 to provide proper spacing. A drum housing depth of less than about 2 mm can make it more difficult to remove the projection layer 94 and the material facing the body 28 from the projection forming surface 156 because the material of the projection layer 94 may expand or move. by fluid flow to the area below the projection-forming surface 156, which in turn can distort the material facing the resulting body 28.
[173] It has however been found that by using a support layer 92 in conjunction with the projection layer 94 as part of the forming process, the distortion of the material facing the resulting two-layer fluid intertwined body 28 can be greatly reduced. and generally facilitates wiper removal of the body-facing material 28 because the dimensionally more stable, less extensible backing layer 92 can absorb the load while the body-facing material 28 is removed from the projection-forming surface 156. The high level that can be applied to the backing layer 92, compared to a single projection layer 94, means that as the material facing the body 28 moves away from the projection-forming surface 156, the projections 90 may exit the forming holes. 170 smoothly in a direction approximately perpendicular to forming surface 168 and coaxially with forming holes 170 in projection forming surface 156. Thus, when using support layer 92, processing speeds can be increased.
[174] To form projections 90 on projection layer 94 and laminate backing layer 92 and projection layer 94 together, one or more fluid interlacing devices 158 may be spaced above projection forming surface 156. The technology The most common one used in this regard may be referred to as spun-bonded or hydroentangled technology, which may use pressurized water as the interlacing fluid. As an unbonded or relatively unbonded web or webs forming the layers (92 and 94) can be fed onto a projection forming surface 156, a multitude of high pressure fluid jets (not shown) from one or more devices. fluid entanglement 158 can move the fibers of the webs and fluid turbulence can effect the intertwining of the fibers. These fluid flows can cause the fibers to be even more intertwined within the individual webs. Fluxes can also cause fiber movement and tangling at the interface of two or more wefts causing the wefts to become joined. Furthermore, if the fibers in a layer, such as projection layer 94, are loosely held together, they may be driven out of their XY plane and therefore in the Z-direction to form projections 90. Depending on the level of necessary intertwining, one or a plurality of such fluid intertwining devices 158 may be used.
[175] In Figure 12, a single fluid interlacing device 158 is shown, but in successive Figures where multiple devices are used in various regions of apparatus 150, they are named with designation letters such as 158a, 158b, 158c, 158d and 158e. When multiple fluid interlacing devices 158 are used, the fluid interlacing pressure in each subsequent fluid interlacing device 158 can be higher than the previous one so that the energy transmitted to the weft or wefts increases and thus the weave of the fiber within or between the wefts increases. This reduces disruption of the general uniformity of the actual web density by the pressurized fluid jets upon reaching the desired level of interlacing and therefore joining the layers and forming the projections 90. Interlacing fluid 176 of fluid interlacing devices 158 may have origin on the injectors through jet strips (not shown) consisting of a line or lines of pressurized fluid jets with small diameter openings generally from about 0.08 to about 0.15 mm and spacing about 0.5 mm in the cross direction of the machine. The pressure in the jets can be between about 5 bar and 400 bar but normally can be less than about 200 bar, except for heavy weight fluid braided materials and when fibrillation is required. Other jet sizes, spacings, jet numbers and jet pressures may be used depending on the final application determined. Such fluid interlocking devices 158 are well known to those of skill in the art and are readily available from manufacturers such as Fleissner of Germany and Andritz-Perfojet of France.
[176] The fluid entanglement device 158 can be provided with conventional hydroentanglement jet strips. Typically, these jet strips can be positioned or spaced from about 5 millimeters to about 10 or 20 millimeters from the projection forming surface 156 although the actual spacing may vary depending on the basis weight of materials being worked, liquid pressure. , the number of individual jets being used, the amount of vacuum being used through the fluid removal system 162, and the speed at which the equipment is being operated.
[177] In the applications shown in Figures 12 through 17 the fluid entanglement devices 158 may be conventional hydroentanglement devices, the construction and operation of which are well known to those skilled in the art. See for example US Patent No. 3,485,706 to Evans, the contents of which are incorporated herein by reference in their entirety for all purposes. See also the description of the hydraulic braiding equipment described by Honeycomb Systems, Inc., of Biddeford, Maine, in the article entitled "Rotary Hydraulic Entanglement of Nonwovens", reproduced from the INSIGHT '86 INTERNATIONAL ADVANCED FORMING/BONDING Conference, the contents of which are incorporated herein by reference in full for all purposes.
[178] Referring to Figure 12, the projection layer 94 can be fed into the apparatus 150 at a speed V1, the support layer 92 can be fed into the apparatus 150 at a speed V2 and the material facing the body 28 can exit apparatus 150 at a speed V3 which is the speed of the projection forming surface 156. As will be explained in more detail below, the speeds V1, V2 and V3 can be the same or varied to alter the formation process and properties of the body contacting material 28. Feeding the projection layer 94 and the backing layer 92 into the apparatus 150 at the same speed (V1 and V2) can produce a body contacting material 28 with the desired projections 90. A feeding the projection layer 94 and the support layer 92 into the apparatus 150 at the same speed, which may be faster than the machine direction speed (V3) of the projection forming surface 156, may also form the desired projections 90 .
[179] Also in Figure 12, there is an optional booster roller 160, which can be driven at a speed Vf. The overfeed roller 160 can be operated at the same speed as the speed V1 of the projection layer 94 or it can be operated at a faster speed to tension the projection layer 94 upstream of the overfeed roller 160 when overfeed is desired. Overfeeding can occur when one or both of the input layers (92 and 94) are introduced to the projection-forming surface 156 at a speed greater than the velocity V3 of the projection-forming surface 156. It has been found that improved projection formation in the projection layer 94 can be affected by feeding the projection layer 94 onto the projection forming surface 156 at a rate greater than the input velocity V2 of the support layer 92. and properties can be obtained by varying the feed rates of the layers (92 and 94) and also using the overfeed roller 160 just upstream of the projection forming surface 156 to provide a greater amount of fibers through the projection layer. 94 for subsequent movement by the entanglement fluid 176 down and into the forming holes 170 in the projection forming surface 156. In particular , by overfeeding the projection layer 94 onto the projection forming surface 156, an improved projection formation can be obtained by including an increased projection height.
[180] To provide an excess of fiber so that the height of projections 90 can be maximized, the projection layer 94 is introduced into the projection forming surface 156 at a surface velocity (V1) greater than the motion (V3) of the projection forming surface 156. Referring to Figure 12, the projection layer 94 is introduced to the projection forming surface 156 at a velocity V1, while the support layer 92 is introduced at a velocity V2 and the surface of projection formation 156 moves at a speed V3 slower than V1 and equal to V2. The overfeed percent (OF - overfeed percent), the ratio at which the projection layer 94 is introduced into the projection forming surface 156, can be set to OF = [(V1 / V3 ) - 1]x100, where Vi is the entry velocity of the projection layer 94 and V3 is the exit velocity of the resulting body contacting material 28 and the velocity of the projection forming surface i56. (When the i60 superfeed roller is being used to increase the speed of the input material on the i56 projection forming surface, it should be noted that the material speed Vi after the i60 superfeed roller will be faster than the speed Vi à amount of overfeed roller i60. When calculating the overfeed ratio, the fastest speed Vi should be used.) Good projection formation 90 was observed when the overfeed ratio is approximately i0 to 50 percent. Also note that this overfeed and ratio technique can be used not only for projection layer 94, but the combination of projection layer 94 and backing layer 92 as they are introduced together into projection forming surface i56.
[181] To minimize the length of the projection layer 94 which is supporting its own weight before being subjected to the i76 entanglement fluid and to prevent wrinkling and bending of the projection layer 94, the i60 overfeed roller can be used to conveying projection layer 94 at speed Vi to a position close to texturing zone i78 on projection forming surface i56. In the example illustrated in Figure 12, the overfeed roller 160 is driven off the conveyor belt 152, but it is also possible to drive it separately so as not to put undue stress on the output projection layer 94. Support layer 92 may be introduced into texturing zone 178 separately from projection layer 94 and at a speed V2 which may be greater than, equal to or less than the speed V3 of projection forming surface 156 and greater, equal to or less than the velocity V1 of the projection layer 94. In one configuration, the support layer 92 may be dragged by the texturing zone 178 by its frictional engagement with the projection layer 94 positioned on the projection forming surface 156 and once over the projection forming surface 156, support layer 92 may have a surface velocity close to the velocity V3 of the projection forming surface 156 or it may be positively introduced into texturing zone 178 at a velocity close to the velocity V3 of the forming surface projection size 156. The texturing process may cause some contraction of the support layer 92 in the machine direction. The overfeed of the support layer 92 or projection layer 94 can be adjusted according to certain materials, equipment and conditions used, so that excess material that is introduced into texturing zone 178 is used up, thus avoiding any corrugation of the resulting body-contacting material 28. As a result, the two layers (92 and 94) will be under some stress at all times, despite the overfeed process. The take-off speed of the body contact material 28 should be arranged to be close to the velocity V3 of the projection forming surface 156 such that excessive stress is not applied to the body contact material 28 during its removal of the projection-forming surface 156. This excessive stress could be detrimental to the clarity and size of the projections 90.
[182] An alternative way of configuring the process and equipment is shown in Figure 13, in which like reference numbers are used for like elements. In this configuration, the main differences from the process and equipment shown in Figure 12 are a pre-entanglement of the projection layer 94 to improve its integrity before further processing through a fluid pre-entanglement device 158a; a lamination from projection layer 94 to backing layer 92 via a fluid entanglement laminating device 158b; and an increase in the number of fluid entanglement devices 158 (so-called fluid entanglement devices for projections 158c, 158d and 158e) and thus an enlargement of the texturing zone 178 on the projection-forming surface 156 in the projection-forming portion. process projections.
[183] Projection layer 94 can be supplied to equipment 150 via conveyor belt 152. As projection layer 94 moves over conveyor belt 152, it is subjected to a first fluid entanglement device. 158a to improve the integrity of the projection layer 94. This may be termed pre-entanglement of the projection layer 94. As a result, this conveyor belt 152 must be fluid permeable to allow the entanglement fluid 176 to pass through the projection layer. 94 and the conveyor belt 152. To remove the applied entanglement fluid 176, as in Figure 12, a fluid removal system 162 may be used below the conveyor belt 152. The fluid pressure of the first fluid entanglement device 158a is generally in the range of approximately 10 to 50 bar.
[184] The backing layer 92 and projection layer 94 can be inserted into a lamination forming surface 180 with the first surface 96 of the backing layer 92 facing and in contact with the lamination forming surface 180 and the second surface 98 of backing layer 92 in contact with inner surface 102 of projection layer 94. 180 lamination to affect fiber entanglement between the two layers (92 and 94). A fluid removal system 162 can be used to dispose of the entanglement fluid 176. To distinguish the equipment in that part of the lamination of the complete process from the subsequent projection forming part where the projections are formed, the equipment and the process are called laminating equipment, as opposed to spray forming equipment. As such, this part relates to the use of a lamination forming surface 180 and a fluid entanglement laminating device 158b which utilizes laminating fluid jets as opposed to the projection forming jets. The lamination forming surface 180 is movable towards the apparatus 150 at a lamination forming surface speed and must be permeable to the entanglement fluid emanating from the laminating fluid jets located in the fluid entanglement laminating device 158b. The fluid entangle laminating device 158b has a plurality of jets of laminating fluid capable of emitting various streams of pressurized laminating fluid from the entanglement fluid 176 toward the laminating forming surface 180. The laminating forming surface 180, when in the configuration of a cylinder as shown in Figure 13, it may have several holes in the surface, separated by landing areas to make it fluid permeable, or it may be made of conventional forming mesh, which is also permeable. In this piece of equipment 150, complete bonding of the two layers (92 and 94) is not required. The process parameters of this part of the equipment are similar to those of the projection forming part, and the description of the equipment and process in connection with Figure 12. Thus, the velocities of the layers (92 and 94) and surfaces in the forming part. Lamination equipment and process can be varied as explained above in relation to the equipment and projection formation process described in relation to Figure 12.
[185] For example, the projection layer 94 can be introduced into the lamination forming process and the support layer 92 at a rate greater than the rate of introduction of the support layer 92 onto the lamination forming surface 180. With respect to entanglement fluid pressures, lower rolling fluid jet pressures are desired in this part of the equipment as additional entanglement of the layers will occur during the projection forming part of the process. As a result, the roll forming pressures of the roll entanglement device 158b will generally range between approximately 30 and 100 bar.
[186] When several flows of laminating fluid 176 in the fluid entanglement laminating device 158b are directed to the outer surface 104 of the projection layer 94 towards the lamination forming surface 180, at least a portion of the fibers in the layer. projection 94 tangle with backing layer 92 to form a laminated web. Once the projection layer 94 and the support layer 92 are joined in a laminated web, the laminated web leaves the laminating part of the equipment and process (elements 158b and 180) and is introduced into the projection forming part of the equipment and process (elements 156, 158c, 158d, 158e and 160 optional). As with the process shown in Figure 12, the laminated web can be fed to the projection-forming surface 156 at the same speed as the projection-forming surface 156 moves or it can be super-fed onto the projection-forming surface 156 using the overfeed roller 160 or, simply causing the laminated web to move at a speed V1 that is greater than the speed V3 of the projection forming surface 156. As a result, the process variables described above with respect to Figure 12, may also be employed with the equipment and process shown in Figure 13. Furthermore, as with the equipment and materials in Figure 12, if the overfeed roller 160 is used to increase the speed V1 of the rolled web as it contacts the projection forming surface 156, it is this faster V1 speed, after the overfeed roller 160, which should be used in calculating the ratio of overfeeding. The same approach should be used in calculating the overfeed ratio with the rest of the embodiments shown in Figures 14 - 17, if material overfeed is used.
[187] In the projection-forming portion of the equipment, a variety of pressurized entangling fluid projection fluid flows 176 may be directed from the fluid jets located in the projection fluid entanglement devices (158c, 158d and 158e) into the laminated web, in a direction from the first surface 96 of the support layer 92, towards the projection forming surface 156 to create a first fiber diversity of the projection layer 94 in the vicinity of the forming holes 170, located on the projection forming surface 156, to be directed into the forming holes 170 and form a plurality of projections 90 which extend outwardly from the outer surface 104 of the projection layer 94, thus forming the material tangled by fluid, in contact with the body 28. As with other processes, the material in contact with the body 28 can be removed from the forming surface. of projection 156 and, if desired, may be subjected to the same or an additional different process as described in connection with the equipment and process in Figure 12, such as drying to remove excess fluid from additional entanglement or binding or other steps. In the projection forming portion of the equipment and apparatus 150, the projection forming pressures of the projection fluid entanglement devices (158c, 158d and 158e) will generally range between about 80 and 200 bar.
[188] Another modification of the process and apparatus 150 of Figure 13 can be illustrated in Figure 14. In Figure 13, as well as the embodiments illustrated in Figures 15 and 17, the material in contact with the fluid matted body 28 may be subjected to a pre-lamination step by means of the lamination forming surface 180 and a fluid entanglement laminating device 158b. In each of these configurations (Figures 13, 15, and 17), the material that is in direct contact with the lamination forming surface 180 is the first surface 96 of the backing layer 92. However, it is also possible to invert the backing layer. support 92 and projection layer 94, as shown in Figure 14, so that outer surface 104 of projection layer 94 is the side that is in direct contact with lamination forming surface 180.
[189] Another embodiment of the process and equipment can be illustrated in Figure 15. This embodiment may be similar to the one shown in Figure 13, except that only the projection layer 94 can be pre-tangled using the fluid entanglement devices 158a and 158b before the projection layer 94 is introduced into the projection forming portion of the equipment. In addition, backing layer 92 may be introduced into texturing zone 178 on projection forming surface 156 in the same manner as in Figure 12, although texturing zone 178 may be provided with multiple fluid entanglement devices (158c, 158d and 158e).
[190] Figure 16 represents another embodiment of the process and equipment which, like Figure 13, can place the projection layer 94 and the support layer 92 in contact with each other, for a lamination treatment in a laminating part of the equipment and process, utilizing a laminating forming surface 180 (which may be the same element as the conveyor belt 152) and a laminating fluid entanglement device 158b. Furthermore, as with the embodiment of Figure 13, in the texturing zone 178 of the projection forming portion of the process and equipment 150, various projection fluid entanglement devices (158c and 158d) may be used.
[191] Figure 17 depicts another embodiment of the process and equipment 150. In Figure 17, the main difference is that the projection layer 94 can be subjected to a first treatment with the entanglement fluid 176, by means of a fluid entanglement device for projection 158c in texturing zone 178 before the second surface 98 of backing layer 92 is contacted with inner surface 102 of projection layer 94 for fluid entanglement, by means of the fluid entanglement device. fluid 158d. In this way, an initial formation of the projections 90 can begin without the support layer 92 being in place. As a result, it may be desirable for the projection fluid entanglement device 158c to be operated at a lower pressure than the projection fluid entanglement device 158d. For example, the projection fluid entanglement device 158c can be operated in a pressure range of 100 to about 140 bar, while the projection fluid entanglement device 158d can be operated in a pressure range of about from 140 to 200 bar. Other combinations and pressure ranges can be chosen depending on the operating conditions of the equipment and the types and basis weights of materials that are used in the projection layer 94 and support layer 92.
[192] In each of the embodiments of the process and equipment 150, the fibers in the projection layer 94 can be sufficiently spaced and movable within the projection web 94 so that the entanglement fluid 176 emanating from the jets of projection fluid in texturing zone 178, is capable of moving a sufficient number of fibers out of the XY plane of projection layer 94, in the vicinity of forming hole holes 170, in projection forming surface 156 and forcing the fibers down and into the forming holes 170, thus forming the projections 90 in the projection layer 94 of the material in contact with the body 28. Furthermore, in overfeeding at least the projection layer 94 to the texturing zone 178, the formation of improved projections can be achieved as shown in the examples and photomicrographs. Secondary lining:
[193] In various embodiments, the liner in contact with the body 28 of the absorbent product 10 can overlap the absorbent body 40 and the outer shield 26, and can insulate the wearer's skin from liquid residues held by the absorbent body 40. In various embodiments, the material in contact with the body 28 can overlap a secondary liner 34. In such embodiments, the secondary liner 34 can overlap the absorbent body 40. In various embodiments, the layer of fluid transfer 78 can be positioned between secondary liner 34 and absorbent body 40. In various embodiments, a pickup layer 84 can be positioned between a secondary liner 34 and absorbent body 40 or a fluid transfer layer 78 , if present. In various embodiments, secondary liner 34 can be joined to capture layer 84, or fluid transfer layer 78, if there is no capture layer 84, by adhesive and/or a dot fusion bond. Dot fusion bonding can be selected from ultrasonic bonding, thermal bonding, pressure bonding and combinations thereof.
[194] In one embodiment, the secondary liner 34 may extend beyond the absorbent body 40 and/or a fluid transfer layer 78, and/or a pickup layer 84, to overlap a portion of the outer cover 26 and may be attached thereto by any means deemed suitable, such as, for example, bonded by adhesive, to substantially enclose absorbent body 40 between outer cover 26 and secondary cover 34. Secondary cover 34 may be narrower than the outer covering 26, but it should be understood that the secondary lining 34 and the outer covering 26 can be the same dimension. It is also possible that the secondary liner 34 does not extend beyond the absorbent body 40 and/or may not be secured to the outer cover 26. The secondary liner 34 may be suitably compatible, soft and non-irritating to the wearer's skin and may be the even as or less hydrophilic than absorbent body 40, to allow body exudates to rapidly penetrate through absorbent body 40 and provide a relatively dry surface for the wearer.
[195] Secondary lining 34 can be manufactured from a wide variety of materials such as synthetic fibers (eg polyester or polypropylene fibers), natural fibers (eg wood or cotton fibers), a combination of natural and synthetic fibers, porous foams, reticulated foams, perforated plastic films or the like. Examples of suitable materials include, but are not limited to, rayon, wood, cotton, polyester, polypropylene, polyethylene, nylon, or other heat-bonded fibers, polyolefins, such as, but not limited to, copolymers of polypropylene and polyethylene, linear polyethylene of low density and aliphatic esters such as polylactic acid, finely perforated film webs, mesh materials and the like, as well as combinations thereof.
[196] Various woven and non-woven structures can be used as the secondary lining 34. The secondary lining 34 can contain a fabric, a non-woven fabric, a polymeric film, a fabric and film laminate, or the like, as well as combinations thereof. Examples of a non-woven fabric may include spunbond fabric, meltblown fabric, coformed fabric, carded weft, carded and bonded weft, bicomponent spunbond fabric, spunlace or the like, as well as combinations thereof.
[197] For example, secondary lining 34 can be composed of a meltblown or heat-welded web of polyolefin fibers. Alternatively, the secondary liner 34 can be a carded and bonded web composed of natural and/or synthetic fibers. The secondary liner 34 can be composed of a highly hydrophobic material, which can optionally be treated with a surfactant, or processed to impart a desired level of water absorbency and hydrophilicity. The surfactant can be applied by any conventional means such as spraying, printing, brush coating or the like. The surfactant can be applied to the entire secondary liner 34 or it can be selectively applied to specific sections of the secondary liner 34. In one embodiment, the secondary liner 34 can be treated with a modifier, which can increase the surface energy of the material. , or reduce the viscoelastic properties of body exudates, such as menses.
[198] In one embodiment, a sideliner 34 may be comprised of a two-component non-woven web. The bicomponent nonwoven weft can be a bicomponent spunbonded weft or a carded and bonded bicomponent weft. An example of a bicomponent staple fiber includes a polyethylene/polypropylene bicomponent fiber. In this particular bicomponent fiber, polypropylene forms the core and polyethylene forms the fiber coating. Fibers with other orientations, such as multilobal, side-by-side, end-to-end may be used without departing from the scope of this disclosure. In one embodiment, a secondary liner 34 can be a heat-welded substrate with a basis weight of about 10 or 12, up to about 15 or 20 g/m 2 . In one embodiment, a secondary liner 34 may be a 12 g/m2 heat-welded-meltblown-thermowelded substrate with a 10% meltblown content applied between the two heat-welded layers.
[199] Although outer shell 26 and secondary liner 34 may include elastomeric materials, it is possible that outer shell 26 and secondary liner 34 could be composed of materials that are generally non-elastomeric. In one embodiment, the secondary liner 34 may be extensible and, more suitably, elastic. In one embodiment, the secondary liner 34 may be suitably stretchable and, more suitably, elastic, at least in the lateral or circumferential direction of the absorbent product 10. In other aspects, the secondary liner 34 may be stretchable and, more suitably, elastic laterally and longitudinally. Retention tabs:
[200] In one embodiment, the containment tabs, 50 and 52, may be secured to the material in contact with body 28 and/or, if present, to the secondary liner 34 of the absorbent product 10, in a generally spaced apart relationship. parallel to each other, laterally within the leg openings 56, to provide a barrier against the flow of body exudates to the leg openings 56. In one embodiment, the containment flaps 50 and 52 may extend longitudinally a from the front waist region 12 of the absorbent product 10, through the genital region 16 to the rear waist region 14 of the absorbent product 10. The containment tabs, 50 and 52, can be joined to the liner in contact with the body 28 and/ or to a secondary liner 34 by an adhesive seam 137 to define a fixed proximal end 138 of containment tabs, 50 and 52.
[201] The containment tabs, 50 and 52, may be made of a fibrous material, which may be similar to the material that forms the material in contact with body 28 and/or secondary liner 34, if present. Other conventional materials, such as polymeric films, can also be used. Each containment tab, 50 and 52, can have a movable distal end 136 that can include tab elastics, such as tab elastics 58 and 60, respectively. Suitable elastic materials for the flap elastic, 58 and 60, can be sheets, threads or tapes of natural rubber, synthetic rubber or thermoplastic elastomeric materials.
[202] The flap elastics, 58 and 60, as illustrated, may have two strands of elastomeric material that extend longitudinally along the distal ends 136 of the containment flaps, 50 and 52, generally parallel, spaced apart from one another. other. The elastic strands may be within the containment tabs, 50 and 52, while in an elastically contractile condition, so that the contraction of the strands brings together and shortens the distal ends 136 of the containment tabs, 50 and 52. As a result, the elastic strands can bias the distal ends 136 of each containment tab, 50 and 52, to a position spaced apart from the proximal end 138 of the containment tabs, 50 and 52, so that the containment tabs 50 and 52 can extend away of the material in contact with the body 28 and/or the secondary liner 34 with a generally vertical orientation of the containment tabs, 50 and 52, especially in the genital region 16 of the absorbent product 10, when the absorbent product 10 is placed on the user. The distal end 136 of the containment tabs, 50 and 52, can be connected to the tab elastics 58 and 60, by partially bending the containment tab, 50 and 52, the material recoils on itself in an amount that may be sufficient to include the flap elastics, 58 and 60. It should be understood, however, that the containment flaps, 50 and 52, may have any number of strands of elastomeric material and may also be omitted from the absorbent product 10 without departing from the scope of this disclosure. Leg elastics:
[203] Elastic leg elements, 66 and 68, can be attached between the inner and outer layers, 70 and 72, respectively, of the outer covering 26, as well as being secured between them by laminated adhesive generally adjacent to the side edges of the inner layer 72 of the outer covering 26. Alternatively, the elastic leg elements 66 and 68 may be disposed between other layers of the absorbent product 10. A wide variety of elastic materials can be used for the elastic leg elements, 66 and 68. Suitable elastic materials can include sheets, filaments or tapes of natural rubber, synthetic rubber or thermoplastic elastomeric materials. Elastic materials can be stretched and secured to a substrate, secured to a joined substrate, or secured to a substrate and then elasticized or shrunk, for example, with the application of heat, such that elastic shrinkage forces are transmitted to the substrate. Closing system:
[204] In one embodiment, the absorbent product 10 may include a closure system. The fastening system may include one or more rear fasteners 140 and one or more front fasteners 142. Portions of the fastening system may be placed in the front waist region 12, rear waist region 14, or both. The closure system can be configured to secure the absorbent product 10 around the wearer's waist and hold the absorbent product 10 in place during use. In one embodiment, the back fasteners 140 can contain one or more materials joined together to form a composite ear, as is known in the art. For example, the composite closure may be formed of a stretch member 144, a non-woven carrier or hook base 146, and a closure member 148. Elastic waist elements:
[205] In one embodiment, the absorbent product 10 may have elastic waist features 62 and 64 which may be formed of any suitable elastic material. In such embodiments, suitable elastic materials can include, but are not limited to, sheets, filaments or tapes of natural rubber, synthetic rubber or thermoplastic elastomeric polymers. Elastic materials can be stretched and bonded to a substrate, bonded to a joined substrate, or bonded to a substrate and then elasticized or shrunk, for example, with the application of heat, such that elastic shrinkage forces are transmitted to the substrate. It should be understood, however, that elastic waist features 62 and 64 may be omitted from the absorbent product 10 without departing from the scope of this disclosure. Side panels:
[206] In one embodiment where the absorbent product 10 may be training pants or panties, youth pants, disposable diapers, or adult absorbent pants, the absorbent product 10 may have front side panels, 182 and 184, and rear side panels, 186 and 188. Figure 18 provides a non-restrictive illustration of an absorbent product 10 that may have side panels, such as front side panels, 182 and 184, and rear side panels, 186 and 188. fronts 182 and 184 and rear side panels 186 and 188 of the absorbent product 10 can be joined to the absorbent product 10 at the respective front and back waist regions, 12 and 14, and can extend outwardly beyond the longitudinal side edges, 18 and 20, of the absorbent product 10. In one example, the front side panels 182 and 184, may be joined to the inner layer 72 of the outer cover 26 as, for example, joining by means of an adhesive, pressing, thermo joining. mica or ultrasonic union. These front side panels, 182 and 184, can also be joined to the outer layer 70 of the outer shell 26 by means of adhesive, pressure, thermal bonding, or ultrasonic bonding. The rear side panels, 186 and 188, can be attached to the outer and inner layers, 70 and 72, respectively, of the outer covering 26 in the back waist region 14 of the absorbent product 10, in much the same way as the front side panels, 182. and 184. Alternatively, the front side panels, 182 and 184, and the rear side panels, 186 and 188, may be formed integrally with the absorbent product 10 as, for example, formed integrally with the outer shield 26, the absorbent material. contact with the body 28, the secondary liner 34, or other layers of the absorbent product 10.
[207] For best fit and appearance, the front side panels 182 and 184, and the rear side panels, 186 and 188, may suitably have a length, measured parallel to the longitudinal axis of the absorbent product 10, of about 20 percent or more, and more suitably about 25 percent or more, of the total length of the absorbent product 10, also measured parallel to the longitudinal axis. For example, the absorbent products 10 that have an overall length of about 54 centimeters, the front side panels, 182 and 184, and the rear side panels, 186 and 188, suitably have an average length of about 10 centimeters or more. and more appropriately, they have an average length of about 15 centimeters. Each of the front side panels, 182 and 184, and the rear side panels, 186 and 188, may be made from one or more distinct individual pieces of material. For example, each front side panel, 182 and 184, and rear side panel, 186 and 188, may include first and second side panel portions (not shown) joined at a seam (not shown), with at least one of the portions containing an elastomeric material. Alternatively, each of the front side panels, 182 and 184, and the rear side panels, 186 and 188, can be made with a single piece of material folded back on itself along an intermediate fold line (not shown).
[208] The front side panels, 182 and 184, and the rear side panels, 186 and 188, may each have an outer edge 190 spaced laterally from the coupling seam 192, an end edge of the leg 194 disposed in the direction. from the longitudinal center of the absorbent product 10, and a waist end edge 196 disposed toward a longitudinal end of the absorbent product 10. The leg end edge 194 and waist end edge 196 may extend from the longitudinal side edges, 18 and 20, from the absorbent product 10 to the outer edges 190. The leg end edges 194 of the front side panels, 182 and 184, and the rear side panels, 186 and 188, may form a portion of the longitudinal side edges, 18 and 20 , of the absorbent product 10. The end edges of the leg 194 of the illustrated absorbent product 10 can be curved and/or angled with respect to the transverse axis to provide a better fit around the wearer's legs. However, it is understood that only one of the trailing edges of leg 194 may be curved or angled, such as the trailing edge of leg 194 of the back waist region 14, or none of the trailing edges of leg 194 may be curved or angled, without departing from the scope of this disclosure. The final edges of the waist 196 may be parallel to the transverse axis. The end waist edges 196 of the front side panels, 182 and 184, may form part of the front waist edge 22 of the absorbent product 10, and the end waist edges 196 of the rear side panels, 186 and 188, may form part of the edge. waist back 24 of the 10 absorbent product.
[209] The front side panels, 182 and 184, and the rear side panels, 186 and 188, may contain an elastic material capable of stretching laterally. Suitable elastic materials, as well as a method described for incorporating elastic front side panels, 182 and 184, and back side panels, 186 and 188, in an absorbent product 10 are described in the following US Patent No. 4,940,464 Issued July 10, 1990 to Van Gompel et al., US Patent No. 5,224,405 Issued July 6, 1993 to Pohjola, US Patent No. 5,104,116 Issued April 14, 1992 to Pohjola and US Patent No. 5,046,272 issued September 10, 1991 to Vogt et al.; all of which are incorporated herein by reference. As an example, suitable elastic materials include a thermal-stretch laminate (STL), a one-way stretch-bonded laminate (NBL), a reversible stretch laminate, or a stretch-bonded laminate (SBL). Methods of preparing such materials are well known to those of skill in the art and are described in US Patent No. 4,663,220 issued May 5, 1987 to Wisneski et al., US Patent No. 5,226. 992 issued July 13, 1993 to Morman and European Patent Application EP No. 0 217 032 published April 8, 1987 in the name of Taylor et al. and PCT application WO 01/88245 in the name of Welch et al., all of which are incorporated herein by reference. Other suitable materials are described in U.S. Patent Application No. 12/649,508 to Welch et al. and 12/023,447 to Lake et al., which are incorporated herein by reference. Alternatively, the front side panels, 182 and 184, and the rear side panels, 186 and 188, may include other woven or non-woven materials, such as those described above as being suitable for outer cover 26 or secondary liner 34, composites mechanically pre-strained, or stretchable but inelastic materials. Feminine hygiene product:
[210] Figure 19 depicts a non-restrictive illustration of an absorbent product 10 in the form of a feminine hygiene product such as a menstrual pad or female adult incontinence product. The absorbent product 10 may have a lengthwise longitudinal direction 30, which may extend along an indicated x axis of the absorbent product 10, and a transverse lateral direction 32 which may extend along an indicated y axis of the absorbent product 10 In addition, the absorbent product 10 may include longitudinally opposed first and second end portions 13 and 15 and an intermediate region 17 located between the end portions 13 and 15. The absorbent product 10 may have first and second side edges. , 18 and 20, which may be the longitudinal sides of the elongated absorbent product 10. The longitudinal side edges, 18 and 20, may be contoured to conform to the shape of the absorbent product 10. The absorbent product 10 can have a desired shape such as, for example, dog bone, race track shape, hourglass shape, or similar. Furthermore, the absorbent product 10 can be substantially longitudinally symmetrical, or it can be longitudinally asymmetrical, as desired.
[211] As shown representatively, the longitudinal dimension of the absorbent product 10 may be relatively greater than the lateral transverse dimension of the absorbent product 10. The configurations of the absorbent product 10 may contain a material in contact with the body 28 and a cover external 26, as described here. An absorbent body 40, as described herein, may be positioned between the material in contact with the body 28 and the outer covering 26. As shown illustratively, for example, the peripheries of the material in contact with the body 28 and the outer covering 26 may be substantially or fully mated or the peripheries of the material in contact with the body 28 and the outer covering 26 may be partially or fully mismatched. In one embodiment, the absorbent product 10 may contain a main liner 34 as described herein. In one embodiment, the absorbent product 10 can include a pickup layer 84 as described herein.
[212] In one embodiment where the absorbent product 10 may be a feminine hygiene product, the absorbent product 10 may contain laterally extending tabs 198 that can be integrally connected to the side edges, 18 and 20, of the absorbent product 10 in the intermediate region 17 of the absorbent product 10. For example, the tabs 198 may be members supplied separately, later attached or operatively joined to the intermediate portion 17 of the absorbent product 10. In other configurations, the tabs 198 can be made unitarily with one or more components of the absorbent product 10. As an example, a flap 198 may be formed by a corresponding existing extension of material in contact with the body 28, a secondary liner 34, if present, an outer covering 26, and combinations thereof.
[213] The flaps 198 may have a designated storage position (not shown) in which the flaps 198 are directed generally inward towards the longitudinally extending centerline 31. In various embodiments, the tab 198 that is connected to a side edge 18 may have a transverse length sufficient to extend and continue beyond the centerline 31 so as to laterally approach the opposite side edge 20 of the product. absorbent 10. The storage position of the flaps 198 can normally represent an arrangement observed when the absorbent product 10 is removed from its wrapping or packaging. Prior to placing the absorbent product 10, as a feminine hygiene product, on the side of an underwear prior to use, the flaps 198 can be selectively arranged so as to extend from the side regions 18 and 20 of the intermediate region 17 of the absorbent product 10. After placing the absorbent product 10 into the underwear, the flaps 198 can be rolled and secured around the side edges of the undergarment so as to help hold the absorbent product 10 in place so that is well known in the area.
[214] The flaps 198 may be of any functional construction and may contain a layer of any functional material. Additionally, each flap 198 can contain a composite material. For example, the flaps 198 may include a heat-welded fabric material, a two-component heat-welded material, a stretch-and heat-welded material, an NBL (neck-stretched-bonded-laminate) material, a meltblown fabric material, a carded and bonded web, a carded and thermally bonded web, a carded and air-bonded web, or the like, as well as combinations thereof.
[215] Each of the tabs 198 may contain a panel fastening member (not shown) that can be operatively attached to a defined engagement surface for the related tabs 198. The panel fastening component may include a system of interlocking mechanical fasteners, a system of adhesive fasteners, or the like, as well as combinations thereof. In one embodiment, one or both tabs 198 may contain a panel fastening system that incorporates a practical adhesive. The adhesive can be solvent based, a hot melt adhesive, a pressure sensitive adhesive, or the like, as well as combinations thereof.
[216] In one embodiment, a garment securing mechanism (not shown) such as a garment securing adhesive may be distributed over the garment side of the absorbent product 10. In one embodiment , the garment adhesive may be distributed over the garment side of the absorbent product 10 of the outer covering 26, and one or more layers or sheets of release material may be positioned on top of the garment adhesive such that they can be removed. , for storage before use. In one embodiment, the garment fastening mechanism may contain a functional component of a mechanical fastening system. In that embodiment, the garment fastening mechanism may contain a functional component of a Velcro fastening system. Bleaching compound:
[217] In one embodiment, a chemical treatment may be employed to change the color of body fluids absorbed by the absorbent product 10. In one embodiment, for example, the treatment may be a debonding compound that binds (agglomerates) red blood cells in blood and menstruation and limit the extent to which the red color of menstruation will be visible. Such a compound includes a surfactant as described in U.S. Patent No. 6,350,711 to TS, et al., which is incorporated herein in its entirety by reference. Non-limiting examples of such surfactants are Pluronic® surfactants (triblock copolymer surfactant), inorganic salts containing a polyvalent anion (eg, bivalent, trivalent, etc.), such as sulfate (SO42-), phosphate (PO43-) , carbonate (CO32-), oxide (O2-), etc., and a monovalent cation such as sodium (Na+), asium (K+), lithium (Li+), ammonium (NH4+), etc. Alkali metal cations are also beneficial. Some examples of salts formed by these ions are, but are not limited to, disodium sulphate (Na2SO4), disodium sulphate (K2SO4), disodium carbonate (Na2CO3), disodium carbonate (K2CO3), monosodium phosphate (NaH2PO4), disodium phosphate (Na2HPO4 ), monobasic phosphate (KH2PO4), disodium phosphate (K2HPO4), etc. Mixtures of the aforementioned salts can also be effective in assisting in the physical separation of red blood cells. For example, a mixture of disodium sulphate (Na2SO4) and mono-sodium phosphate (KH2PO4) can be used.
[218] In addition to binding agents, the bleaching compound can alter the chemical structure of hemoglobin to change its color. Examples of such compositions are described in Patent Application Publication No. 2009/0062764 to MacDonald, et al., which is incorporated herein in its entirety by reference. In one embodiment, the compound may include an oxidizing agent which may generally be able to oxidize hemoglobins or other substances responsible for the undesirable color of bodily fluids. Some examples of oxidizing agents are, but are not limited to, peroxygen bleaches (eg hydrogen peroxide, percarbonates, persulfates, perborates, peroxyacids, alkyl hydroperoxides, peroxides, diacyl peroxides, ozonides, superoxides, oxo-ozonides and periodates) ; hydroperoxides (eg tert-butyl hydroperoxide, cumyl hydroperoxide, 2,4,4-trimethylpentyl-2-hydroperoxide, diisopropylbenzene-monohydroperoxide, tert-amyl hydroperoxide and 2,5-dimethyl-hexane-2,5- dihydroperoxide); peroxides (eg lithium peroxide, sodium peroxide, potassium peroxide, ammonium peroxide, calcium peroxide, rubidium peroxide, cesium peroxide, strontium peroxide, barium peroxide, magnesium peroxide, mercury peroxide, peroxide silver, zirconium peroxide, hafnium peroxide, titanium peroxide, phosphorus peroxide, sulfur peroxide, rhenium peroxide, iron peroxide, cobalt peroxide and nickel peroxide); perborates (eg sodium perborate, asium perborate and ammonium perborate); persulfates (eg sodium persulfate, potassium dipersulfate and potassium persulfate); and so on. Other oxidizing agents are, but are not limited to, omega-3 and -6 fatty acids such as linoleic acid, alpha-linolenic acid, arachidonic acid, eicosapentaenoic acid, docosahexaenoic acid, eicosadienoic acid, eicosatrienoic acid, etc.
[219] The bleaching compound can be applied to any liquid-permeable layer of the absorbent product 10 where it may come into contact with aqueous fluids expelled from the body such as menstruation, such as the body-contacting layer 28 , secondary liner 34, capture layer 84, fluid transfer layer 78, absorbent body 40, outer shield 26, and combinations thereof. In one embodiment, the bleaching compound can be applied to only a portion of the surface of the layers to which it is applied, so as to ensure that the layers are still able to retain sufficient absorbent properties. In one embodiment, it may be desired that the bleaching compound be positioned closer to the absorbent body 40. In one embodiment, an additional layer (not shown) can be employed on an absorbent product 10 and can be applied with the compound. decolorizer that is in contact with the absorbent body 40. The additional layer can be composed of a variety of different porous materials such as a perforated film, a non-woven web (eg, cellulose web, heat-welded web, meltblown web , etc.), foams, etc. In one embodiment, the additional layer may be in the form of a flat envelope (e.g., sachet, bag, etc.) folded so as to partially or completely surround the absorbent body 40. The bleach compound may be disposed with its envelope , so that it remains sealed in place before use. Non-restrictive examples of embodiments of absorbent products:
[220] In one embodiment, an absorbent product 10 may have an outer cover 26, an absorbent body 40 and a material 28 in contact with the body. In this embodiment, the material 28 in contact with the body may have a backing layer 92 and a projection layer 94. In this embodiment, the projection layer 94 may have an inner 102 and outer 104 surface and may have several hollow projections 90 extending from outer surface 104 of projection layer 94. In various embodiments, material 28 in contact with the body of absorbent product 10 may further contain a landing area 116 with an open area greater than approximately 1% within a selected area of the material contacting the body 28, projections 90 less than approximately 1% open area within a selected area of the material 28 contacting the body, various fibers of the projection layer 94 entangled with the support layer 92, a load greater than approx. 2 Newtons per 25 mm wide at 10% machine direction extension, projections 90 with height greater than approx. 1 mm, a resilience greater than approx. approximately 70% and combinations thereof. In various embodiments, absorbent product 10 may further include a second secondary liner 34 positioned between material 28 in contact with the body and absorbent body 40. In various embodiments, absorbent body 40 may be free of material. super absorbent. In various embodiments, absorbent body 40 can contain greater than about 15% superabsorbent material. In various embodiments, the open area of the projections 90 may be due to interstitial spacing between the fibers. In various embodiments, the open area of the landing areas 116 may be due to interstitial spacing between the fibers.
[221] In one embodiment, an absorbent product 10 may have an outer covering 26, an absorbent body 40, a material 28 in contact with the body, and a secondary liner 34 positioned between the material 28 in contact with the body and the absorbent body 40. In this embodiment, the material 28 in contact with the body may have a backing layer 92 and a projection layer 94. In this embodiment, the projection layer 94 may have an inner 102 and outer 104 surface. and may have a plurality of hollow projections 90 extending from the outer surface 104 of projection layer 94. In various embodiments, the material 28 in contact with the body of the absorbent product 10 may further contain a landing area 116 having an area open greater than approximately 1% within a selected area of the material in contact with the body 28, projections 90 less than approximately 1% of open area within a chosen area of the material 28 in contact with the body, various fi bras of projection layer 94 tangled with support layer 92, a load greater than approximately 2 Newtons per 25 mm wide at 10% machine direction extension, projections 90 with height greater than approximately 1 mm, a resilience greater than approximately 70% and combinations thereof. In various embodiments, absorbent body 40 can be free of superabsorbent material. In various embodiments, absorbent body 40 can contain greater than about 15% superabsorbent material. In various embodiments, the open area of the projections 90 may be due to interstitial spacing between the fibers. In various embodiments, the open area of the landing areas 116 may be due to interstitial spacing between the fibers.
[222] In one embodiment, an absorbent product 10 may have an outer cover 26, an absorbent body 40 and a material 28 in contact with the body. In this embodiment, the material 28 in contact with the body may have a backing layer 92 and a projection layer 94. In this embodiment, the projection layer 94 may have an inner 102 and outer 104 surface and may have several hollow projections 90 extending from the outer surface 104 of the projection layer 94. In such an embodiment, the material 28 facing the body may still have a load greater than approximately 2 Newtons per 25mm width at 10% of extension in the machine direction. In various embodiments, the body-facing material 28 of the absorbent product 10 may further contain a landing area 116 with an open area greater than approximately 1% within a selected area of the body-facing material 28 , projections less than approximately 1% open area within a selected area of material 28 facing the body, various fibers of projection layer 94 entangled with backing layer 92, projections 90 greater than about 1 mm in height , a resilience greater than approximately 70% of combinations of these. In various embodiments, absorbent product 10 may further include a second secondary liner 34 positioned between material 28 in contact with the body and absorbent body 40. In various embodiments, absorbent body 40 may be free of material. super absorbent. In various embodiments, absorbent body 40 can contain greater than about 15% superabsorbent material. In various embodiments, the open area of the projections 90 may be due to interstitial spacing between the fibers. In various embodiments, the open area of the landing areas 116 may be due to interstitial spacing between the fibers.
[223] In one embodiment, an absorbent product 10 may have an outer cover 26, an absorbent body 40, and a material 28 in contact with the body. In this embodiment, the material 28 in contact with the body may have a backing layer 92 and a projection layer 94. In this embodiment, the projection layer 94 may have an inner 102 and outer 104 surface and may have several hollow projections 90 extending from the outer surface 104 of the projection layer 94. In such an embodiment, the body facing material 28 may exhibit a resilience greater than approximately 70%. In various embodiments, the material 28 of the absorbent product 10 may further contain a landing area 116 with an open area greater than approximately 1% within a selected area of the material facing the body 28, projections less than approximately 1 % open area within a chosen area of material 28 facing the body, various fibers from projection layer 94 entangled with backing layer 92, a load greater than approximately 2 Newtons per 25 mm wide at 10% of machine direction extension, projections 90 greater than approximately 1 mm in height, and combinations thereof. In various embodiments, absorbent product 10 may further include a second secondary liner 34 positioned between material 28 in contact with the body and absorbent body 40. In various embodiments, absorbent body 40 may be free of material. super absorbent. In various embodiments, absorbent body 40 can contain greater than about 15% superabsorbent material. In various embodiments, the open area of the projections 90 may be due to interstitial spacing between the fibers. In various embodiments, the open area of the landing areas 116 may be due to interstitial spacing between the fibers.
[224] In one embodiment, an absorbent product 10 may have an outer covering 26, an absorbent body 40 and a body facing material 28, which may have a support layer 92 and a projection layer 94. Projection layer 94 may have an inner 102 and outer surface 104 and may have a plurality of hollow projections 90 extending from the outer surface 104 of projection layer 94. In such an embodiment, the material 28 faces the body. may have a landing area 116 which may have an open area greater than approximately 1% within a selected area of material 28 facing the body and projections 90 with less than 1% open area within a chosen area of material 28 which faces the body. In various embodiments, material 28 facing the body of absorbent product 10 may further contain several fibers from projection layer 94 entangled with backing layer 92, a load greater than approximately 2 Newtons per 25mm width at 10% machine direction extension, 90 projections with a height greater than approx. 1 mm, a resilience greater than approx. 70% and combinations of these. In various embodiments, absorbent product 10 may further include a second secondary liner 34 positioned between material 28 in contact with the body and absorbent body 40. In various embodiments, absorbent body 40 may be free of material. super absorbent. In various embodiments, absorbent body 40 can contain greater than about 15% superabsorbent material. In various embodiments, the open area of the projections 90 may be due to interstitial spacing between the fibers. In various embodiments, the open area of the landing areas 116 may be due to interstitial spacing between the fibers. In various embodiments, the amount of faecal waste specimens remaining in the material 28 facing the body shortly after the emission of the faecal waste specimens according to the described test method is less than approximately 2.5 grams.
[225] In one embodiment, an absorbent product 10 may have an outer covering 26, an absorbent body 40, a body-facing material 28, and a fluid transfer layer 78 positioned between the absorbent body 40 and the material 28 that faces the body. In this embodiment, the material 28 in contact with the body may have a backing layer 92 and a projection layer 94. In this embodiment, the projection layer 94 may have an inner 102 and outer 104 surface and may have several hollow projections 90 extending from outer surface 104 of projection layer 94. In various applications, the fluid transfer layer can contain a polymeric material. In various embodiments, the body-facing material 28 of the absorbent product 10 may further contain a landing area 116 with an open area greater than approximately 1% within a selected area of the body-facing material 28 , projections 90 less than approximately 1% open area within a selected area of material 28 facing the body, various fibers from projection layer 94 entangled with support layer 92, a load greater than approximately 2 Newtons per 25 mm wide at 10% machine direction extensions, 90 projections with a height greater than approx. 1 mm, a resilience greater than approx. 70% and combinations of these. In various embodiments, absorbent body 40 can be free of superabsorbent material. In various embodiments, absorbent body 40 can contain greater than about 15% superabsorbent material. In various embodiments, the open area of the projections 90 may be due to interstitial spacing between the fibers. In various embodiments, the open area of the landing areas 116 may be due to interstitial spacing between the fibers. In various embodiments, the amount of faecal waste specimens remaining in the material 28 facing the body shortly after the emission of the faecal waste specimens according to the described test method is less than approximately 2.5 grams.
[226] In one embodiment, an absorbent product 10 may have an outer covering 26, an absorbent body 40, a body-facing material 28, a catch layer 84 positioned between the absorbent body 40 and the material that faces the body. faces the body 28, and a fluid transfer layer 78 positioned between the catchment layer 84 and the absorbent body 40. In this embodiment, the material 28 in contact with the body may have a backing layer 92 and a projection layer 94. In this embodiment, projection layer 94 may have an inner surface 102 and outer surface 104 and may have a plurality of hollow projections 90 extending from outer surface 104 of projection layer 94. In various embodiments , pickup layer 84 can contain fibers having a denier less than approximately 5. In various embodiments, fluid transfer layer 78 can contain a cellulosic material. In various embodiments, the body-facing material 28 of the absorbent product 10 may further contain a landing area 116 with an open area greater than approximately 1% within a selected area of the body-facing material 28 , projections 90 less than approximately 1% open area within a selected area of material 28 facing the body, various fibers from projection layer 94 entangled with support layer 92, a load greater than approximately 2 Newtons per 25 mm wide at 10% machine direction extensions, 90 projections with a height greater than approx. 1 mm, a resilience greater than approx. 70% and combinations of these. In various embodiments, absorbent body 40 can be free of superabsorbent material. In various embodiments, absorbent body 40 can contain greater than about 15% superabsorbent material. In various embodiments, the open area of the projections 90 may be due to interstitial spacing between the fibers. In various embodiments, the open area of the landing areas 116 may be due to interstitial spacing between the fibers. In various embodiments, the amount of faecal waste specimens remaining in the material 28 facing the body shortly after the emission of the faecal waste specimens according to the described test method is less than approximately 2.5 grams.
[227] In one embodiment, an absorbent product 10 may have an outer covering 26, an absorbent body 40, a body facing material 28 which may have a support layer 92 and a projection layer 94, and a transfer layer 78 positioned between the absorbent body 40 and the material 28 facing the body. Projection layer 94 may have an inner 102 and outer surface 104 and may have a plurality of hollow projections 90 extending from the outer surface 104 of projection layer 94. In such an embodiment, the material 28 faces the body. may have a landing area 116 which may have an open area greater than approximately 10% within a selected area of material 28 facing the body and projections 90 with less than 1% open area within a chosen area of material 28 which faces the body. In various embodiments, material 28 facing the body of absorbent product 10 may further contain several fibers from projection layer 94 entangled with backing layer 92, a load greater than approximately 2 Newtons per 25mm width at 10% machine direction extension, 90 projections with a height greater than approx. 1 mm, a resilience greater than approx. 70% and combinations of these. In various embodiments, absorbent body 40 can be free of superabsorbent material. In various embodiments, absorbent body 40 can contain greater than about 15% superabsorbent material. In various embodiments, the open area of the projections 90 may be due to interstitial spacing between the fibers. In various embodiments, the open area of the landing areas 116 may be due to interstitial spacing between the fibers. In various embodiments, the amount of faecal waste specimens remaining in the material 28 facing the body shortly after the emission of the faecal waste specimens according to the described test method is less than approximately 2.5 grams.
[228] In one embodiment, an absorbent product 10 may have an outer covering 26, an absorbent body 40, a body-facing material 28, a catch layer 84 positioned between the absorbent body 40 and the material that faces the body. faces the body 28, and a fluid transfer layer 78 positioned between the pickup layer 84 and the absorbent body 40. In such an embodiment, the fluid transfer layer 78 may contain a polymeric material. In this embodiment, the material 28 in contact with the body may have a backing layer 92 and a projection layer 94. In this embodiment, the projection layer 94 may have an inner 102 and outer 104 surface and may have several hollow projections 90 extending from outer surface 104 of projection layer 94. In various embodiments, capture layer 84 may contain fibers having a denier greater than approximately 5. In various embodiments, the material 28 is facing. for the absorbent product body 10 may further contain a landing area 116 with an open area greater than approximately 1% within a selected area of the material facing the body 28, projections 90 less than approximately 1% open area within from a selected area of material 28 facing the body, several fibers from projection layer 94 entangled with backing layer 92, a load greater than approximately 2 Newtons per 25 mm of l. thickness in 10% machine direction, projections 90 with height greater than approx. 1 mm, a resilience greater than approx. 70% and combinations of these. In various embodiments, absorbent body 40 can be free of superabsorbent material. In various embodiments, absorbent body 40 can contain greater than about 15% superabsorbent material. In various embodiments, the open area of the projections 90 may be due to interstitial spacing between the fibers. In various embodiments, the open area of the landing areas 116 may be due to interstitial spacing between the fibers. In various embodiments, the faecal material waste simulacrum propagation area in the material 28 that faces the body just after the emission of the faecal material waste simulacrum in accordance with the test method described herein may be less than approximately 34 cm2.
[229] In one embodiment, an absorbent product 10 may have an outer cover 26, an absorbent body 40, a body-facing material 28 with a landing area 116 with an open area greater than 5% within an area selected from the body facing material 28, a pickup layer 84 positioned between the absorbent body 40 and the body facing material 28, and a fluid transfer layer 78 positioned between the pickup layer 84 and the absorbent body 40. In various embodiments, fluid transfer layer 78 can contain a cellulosic material. In that embodiment, the material 28 in contact with the body may have a backing layer 92 and a projection layer 94. In such an embodiment, the projection layer 94 may contain an inner surface 102 and an outer surface 104, and may contain a plurality of hollow projections 90 extending from the outer surface 104 of the projection layer 94, where the projections have less than 1% open area within a selected area of the material facing the body. In various embodiments, capture layer 84 can contain fibers with denier greater than approximately 5. In various embodiments, capture layer 84 can contain fibers with denier less than approximately 5. In various embodiments, the material 28 facing the body of absorbent product 10 may further contain several fibers from projection layer 94 entangled with backing layer 92, a load greater than approximately 2 Newtons per 25mm width at 10% machine direction extension , 90 projections with a height greater than approximately 1 mm, a resilience greater than approximately 70%, and combinations of these. In various embodiments, absorbent body 40 can be free of superabsorbent material. In various embodiments, absorbent body 40 can contain greater than about 15% superabsorbent material. In various embodiments, the open area of the projections 90 may be due to interstitial spacing between the fibers. In various embodiments, the open area of the landing areas 116 may be due to interstitial spacing between the fibers. In various embodiments, the faecal material waste simulacrum propagation area in the material 28 that faces the body just after the emission of the faecal material waste simulacrum in accordance with the test method described herein may be less than approximately 34 cm 2 .
[230] In one embodiment, an absorbent product 10 may have an outer covering 26, an absorbent body 40, a body-facing material 28, a catch layer 84 positioned between the absorbent body 40 and the material that faces the body. faces body 28, and a fluid transfer layer 78 positioned between capture layer 84 and absorbent body 40. In various embodiments, fluid transfer layer 78 can contain a cellulosic material. In this embodiment, the material 28 in contact with the body may have a backing layer 92 and a projection layer 94. In this embodiment, the projection layer 94 may have an inner 102 and outer 104 surface and may have several hollow projections 90 extending from outer surface 104 of projection layer 94. In various embodiments, capture layer 84 can contain fibers with denier greater than approximately 5. In various embodiments, capture layer 84 may contain fibers of less than approximately 5 denier. In various embodiments, the material 28 facing the body of the absorbent product 10 may further contain several fibers from the projection layer 94 entangled with the backing layer 92, a load greater than approximately 2 Newtons per 25 mm wide at 10% machine direction extensions, 90 projections greater than approximately 1 mm in height, projections less than 1% open area within an area chosen from material 28 facing the body, a resilience greater than approximately 70% and combinations thereof. In various embodiments, the body-facing material 28 may have a landing area 116 and the landing area 116 may have an open area greater than approximately 1% within a selected area of the facing material 28. the body. In various embodiments, absorbent body 40 can be free of superabsorbent material. In various embodiments, absorbent body 40 can contain greater than about 15% superabsorbent material. In various embodiments, the open area of the projections 90 is due to the interstitial spacing between the fibers. In various embodiments, the open area of the landing areas 116 is due to the interstitial spacing between the fibers. In various embodiments, the faecal material waste simulacrum propagation area in the material 28 that faces the body just after the emission of the faecal material waste simulacrum in accordance with the test method described herein may be less than approximately 34 cm2.
[231] In one embodiment, an absorbent product 10 may have an outer cover 26, an absorbent body 40, and a material 28 in contact with the body. In this embodiment, the material 28 in contact with the body may have a backing layer 92 and a projection layer 94. In this embodiment, the projection layer 94 may have an inner 102 and outer 104 surface and may have several hollow projections 90 extending from the outer surface 104 of the projection layer 94. In such an embodiment, the absorbent product 10 may have a second menstruation simulacrum receiving time by means of the material 28 facing the body. , less than approximately 30 seconds after the occurrence with a menstrual sham, in accordance with the influx/rehumidification test method described herein. In various embodiments, the body facing material 28 may further contain a landing area 116 with an open area greater than approximately 1% within a selected area of the body facing material 28, lower projections 90 at approximately 1% open area within a selected area of material 28 facing the body, several fibers from projection layer 94 entangled with backing layer 92, a load greater than approximately 2 Newtons per 25 mm wide at 10% machine direction extension, 90 projections with a height greater than approx. 1 mm, a resilience greater than approx. 70% and combinations of these. In various embodiments, absorbent product 10 may further include a second secondary liner 34 positioned between material 28 in contact with the body and absorbent body 40. In various embodiments, absorbent body 40 may be free of material. super absorbent. In various embodiments, absorbent body 40 can contain greater than about 15% superabsorbent material. In various embodiments, the open area of the landing areas 116 may be due to interstitial spacing between the fibers.
[232] In one embodiment, an absorbent product 10 may have an outer covering 26, an absorbent body 40, a body-facing material 28, and a secondary liner 34 positioned between the body-facing material 28. and the absorbent body 40. In this embodiment, the material 28 in contact with the body may have a backing layer 92 and a projection layer 94. In this embodiment, the projection layer 94 may have an inner surface 102 and outer surface 104 and may have a plurality of hollow projections 90 extending from outer surface 104 of projection layer 94. In such an embodiment, absorbent product 10 may have a second menstrual simulacrum receiving time by means of material 28 which faces the body, less than approximately 30 seconds after the occurrence with simulacrum of menstruation, according to the inflow/rewetting test method described herein. In various embodiments, the body facing material 28 may further contain a landing area 116 with an open area greater than approximately 1% within a selected area of the body facing material 28, lower projections 90 at approximately 1% open area within a selected area of material 28 facing the body, several fibers from projection layer 94 entangled with backing layer 92, a load greater than approximately 2 Newtons per 25 mm wide at 10% machine direction extension, 90 projections with a height greater than approx. 1 mm, a resilience greater than approx. 70% and combinations of these. In various embodiments, absorbent body 40 can be free of superabsorbent material. In various embodiments, absorbent body 40 can contain greater than about 15% superabsorbent material. In various embodiments, the open area of the landing areas 116 may be due to interstitial spacing between the fibers. Method to determine the percentage of open area
[233] Percent open area can be determined using the image analysis measurement method described in this document. In this context, the open area is considered as the regions within a material in which light transmitted from a light source passes directly through these regions, without obstacles, in the material of interest. In general, the image analysis method determines a numerical value of percentage of open area for a material through specific image analysis measurement parameters, such as area. The percentage open area method is performed using conventional optical image analysis techniques to detect regions of open areas in both the landing and projection areas separately and then calculate the percentages in each. To separate the landing areas and projections for detection and subsequent measurement, incident lighting is used along with the image processing steps. An image analysis system, controlled by an algorithm, performs detection, image processing and measurement, and also transmits data digitally to a spreadsheet database. The resulting measurement data is used to determine the percentage of open area for materials that have landing areas and projections.
[234] The method for determining the percentage of open area in both the landing areas and the projections of a given material includes the step of acquiring two separate digital images of the material. An example setup for capturing the image is illustrated in Figure 20. Specifically, a CCD 200 video camera (for example, a Leica DFC 310 FX video camera operated in grayscale mode and marketed by Leica Microsystems, of Heerbrugg, Switzerland) is mounted on a standard 202 mount, such as a standard Polaroid MP-4 Land Camera mount, marketed by the Polaroid Resource Center in Cambridge, Massachusetts. The 202 pattern bracket is attached to a macro viewer 204 such as a KREONITE macro viewer marketed by Dunning Photo Equipment, Inc., with a facility in Bixby, Oklahoma. An automatic stage 208 is placed on the top surface 206 of the macro viewer 204. The automatic stage 208 is used to automatically move the position of a material for viewing by the camera 200. A suitable automatic stage is the model H112 offered by Prior Scientific Inc. , with an office in Rockland, MA.
[235] Material containing landing areas and projections is placed in the automatic stage 208 under the optical axis of a Nikon AF Nikkor 210 mm lens with an f4 aperture setting. The Nikon 210 lens is attached to the Leica camera DFC 310 FX 200 using a "c" bracket adapter. The distance D1 from the front face 212 of the Nikon 210 lens to the material is 21 cm. The material is laid out flat on the automatic stage 208 and any wrinkles are removed by stretching and/or fixing it to the surface of the automatic stage 208, with transparent adhesive tape on its outer edges. The material is positioned so that the machine direction (MD) is in the horizontal direction of the resulting image. The surface of the material is illuminated with incident fluorescent light, provided by a 40 watt 16-inch diameter GE Circline fluorescent lamp. The lamp 214 is fixed to a bracket positioned centrally over the material and under the video camera above. , at a D2 distance of 3 inches above the surface of the material. The light level of the lamp 214 is controlled by a variable autotransformer type 3PN1010, marketed by Staco Energy Products Co., with a plant in Dayton, OH. Transmitted light is also supplied to the material below the automatic stage 208 by a bank of five 20 watt fluorescent lamps 218 covered by a diffuser plate 220. The diffuser plate 220 is inserted and forms a part of the upper surface 206 of the macro viewer 204. The diffuser plate 220 is overlaid with a black mask 222 which has an aperture of 3 inches by 3 inches 224. The aperture 224 is positioned so that it is centered under the optical axis of the Leica camera and lens system. The distance D3 from aperture 224 to the surface of automatic stage 208 is approximately 17 cm. The lighting level of the 218 fluorescent light bank is also controlled by an independent variable autotransformer.
[236] The image analysis software platform used to perform percentage open area measurements is a QWIN Pro (version 3.5.1) offered by Leica Microsystems, with an office in Heerbrugg, Switzerland. The system and images are also calibrated using QWIN software and a standard ruler with metric markings accurate to within a millimeter. Calibration is performed on the horizontal dimension of the video camera image. Units of millimeters per pixel are used for calibration.
[237] The method of determining the percentage open area of a material includes the step of taking multiple measurements of the area of both incident and transmitted light images. Specifically, an image analysis algorithm is used to acquire and process images as well as perform measurements using the User Interactive Programming System (QUIPS) language Quantimet. The image analysis algorithm is reproduced below. NAME = % open area - Landing vs projection regions-1 PURPOSE = Measures % open area or 'landing' and 'projection' regions using the 'sandwich' lighting technique SETTING VARIABLES AND OPENING FILES Open file ( C: Data39291% Open Areadata.xls, channel #1 ) MFLDIMAGE = 2 TOTCOUNT = 0 TOTFIELDS = 0 SAMPLE ID AND CONFIGURATION Configure (Storage 1392 x 1040 images, Gray images 81, Binary 24) Enter results header File Results Header (channel #1) File line (channel #1) Picture Setup DC Twain [PAUSE] ( Camera 1, Auto Exposure Off, Gain 0.00, Exposure Time 34.23 ms, Brightness 0, Lamp 38.83) Measurement frame ( x 31, y 61, Width 1330, Height 978) Image frame ( x 0, y 0, Width 1392, Height 1040 ) --Calvalue = 0 .0231 mm/px CALVALUE = 0.0231 Calibrate ( CALVALUE CALUNITS$ per pixel ) Clear Accepted For ( SAMPLE = 1 to 1, step 1 ) Clear Accepted File ( "Field No.", channel no. 1, width of ç scope: 9, left justified) Archive ("Landing area", channel #1, field width: 9, left justified) Archive ("Landing area open", channel #1, field width : 13, left-justified ) File ("% of Open Landing Area", channel #1, field width: 15, left-justified ) File ("Open Landing Area" Proj. Area", channel #1, field width: 9, left-justified ) File ( "Proj open area Open area, channel #1, field width: 13, left justified ) File ("% Open Area Proj . Area", channel #1, field width: 15, left justified ) File ("% Total Open Area", channel #1, field width: 14, left justified ) File line ( channel n º 1 ) Stage ( Set Origin ) Stage ( Reading pattern, fields 5 x 1, size 82500.000000 x 82500.000000 ) IMAGE ACQUISITION I - Projection isolation To ( FIELD = 1 to 5, step 1 ) Display ( Image0 (on) , frames (on, on), planes (off, off, off, off, off, off), lut 0, x 0, y 0, z 1, Reduction off ) Pause text ("Check whether incident lighting is correct" (WL = 0.88 - 0.94) and acquire image." Picture Setting DC Twain [PAUSE] ( Camera 1, Auto Exposure Off, Gain 0.00, Exposure Time 34.23 ms, Brightness 0, Lamp 38 .83 ) Capture ( for Image0 ) DETECT - Projections only Pause text ("Check that the threshold is set at least to the right of the gray level histogram peak to the left histogram peak corresponding to the 'landing' region". Detect [PAUSE] (clearer than 127, from Image0 to Binary0 outlined ) BINARY IMAGE PROCESSING Fix Binary (closed from Binary0 to Binary1, cycles 10, Operator disk, edge erosion on ) Identify Binary (Fill holes from Binary1 to Binary1 ) Fix Binary (open from Binary1 to Binary2, cycles 20, Operator disk, edge erosion on ) Fix Binary (closed from Binary2 to Binary3, cycles 8, Operator disk, edge erosion on ) Pause text ("Toggle <control keys" > and <b>to check collision detection and correct if necessary." Edit Binary [PAUSE] ( Draw from Binary3 to Binary3, nib Fill, width 2) Logical Binary ( copy Binary3, Invert to Binary4) IMAGE ACQUISITION 2 - % Open area Display ( Image0 (on), frames (on, on), planes (off, off, off, off, off, off), lut 0, x 0, y 0, z 1, Reduction off ) Pause text ( "Turn off the incident light and check Check if transmitted illumination is correct (WL = 0.97) and capture image." Picture Setting DC Twain [PAUSE] ( Camera 1, Auto Exposure Off, Gain 0.00, Exposure Time 34.23 ms, Brightness 0, Lamp 38.83) Capture ( to Image0 ) DETECT - Only open areas Detect ( clearer than 210, from Image0 to Binary10 outlined ) BINARY IMAGE PROCESSING Binary logic ( C = AEB: C Binary11, A Binary3, B Binary10 ) Binary logic ( C = AEB: C Binary12, A Binary4, B Binary10 ) MEASURE AREAS - Landing, projections, open area in each - - Landing area MFLDIMAGE = 4 Field Measurement (plane MFLDIMAGE, in FLDRESULTS(1), statistics in FLDSTATS(7) ,1) ) Selected parameters: Area LANDAREA = FLDRESULTS(1) - - Projection area MFLDIMAGE = 3 Field Measurement (plane MFLDIMAGE, in FLDRESULTS(1), statistics in FLDSTATS(7,1) ) Selected parameters: Area BUMPAREA = FLDRESULTS(1) - - Open projection area MFLDIMAGE = 11 Field Measurement (plane MFLDIMAGE, in FLDRESU LTS(1), statistics in FLDSTATS(7,1) ) Selected parameters: Area APBUMPAREA = FLDRESULTS(1) - - Open landing area MFLDIMAGE = 12 Field Measurement (plane MFLDIMAGE, in FLDRESULTS(1), statistics in FLDSTATS( 7,1) ) Selected parameters: Area APLANDAREA = FLDRESULTS(1) - - % total open area MFLDIMAGE = 10 Field Measurement (plane MFLDIMAGE, in FLDRESULTS(1), statistics in FLDSTATS(7,1) ) Selected parameters: %Area TOTPERCAPAREA = FLDRESULTS(1) CALCULATE AND GENERATE AREAS RESULT PERCAPLANDAREA = APLANDAREA/LANDAREA*100 PERCAPBUMPAREA = APBUMPAREA/BUMPAREA*100 File ( FIELD, channel #1, 0 digit after '.' File ( LANDAREA, channel #1) , 2 digits after '.' File ( APLANDAREA, channel #1, 2 digits after '.' File ( PERCAPLANDAREA, channel #1, 1 digit after '.' File ( BUMPAREA, channel #1, 2 digits after '.' '.' File ( APBUMPAREA, channel #1, 4 digits after '.' File ( PERCAPBUMPAREA, channel #1, 5 digits after '.' File ( TOTPERCAPAREA, cane) l #1, 2 digits after '.' File line (channel #1) Stage (Step, Wait until it stops + 1100 ms) Next ( FIELD ) Pause text ( "If there are no more samples, enter '0 .'" ) Input (FINISH) If ( FINISH=0 ) Go to RESULT Endif Pause text ( "Place the next replicated sample in the automatic stage, turn the incident light on and turn off and/or block the substage light". Picture Setting DC Twain [PAUSE] ( Camera 1, Auto Exposure Off, Gain 0.00, Exposure Time 34.23 ms, Brightness 0, Lamp 38.83) File Line (Channel #1) Next ( SAMPLE ) RESULT: Close file (channel #1) END
[238] The QUIPS algorithm is run with the QWIN Pro software platform. The analyst is initially asked to enter the material set information that is sent to the Excel file.
[239] The analyst is then presented with a live image setup window, on the computer screen, to place a material in automatic stage 208. The material must be laid flat and light force must be applied to its edges to remove any macro wrinkles that may be present. It must also be aligned so that the machine direction runs horizontally across the image. At this time, the Circline 214 fluorescent lamp can be turned on to aid in positioning the material. The analyst then adjusts the Circline 214 incident fluorescent lamp via the variable autotransformer to read a white level of approximately 0.9. Substage 218 transmitted light bank must also be turned off at this time or masked with a piece of black construction paper to block the light, positioned over the 3-inch by 3-inch opening 224.
[240] The analyst should now verify that the detection threshold is set to the appropriate level of detection of projections using the Detection window, which is displayed on the computer's monitor screen. Traditionally, the threshold is set using white mode at a point approximately near the middle of the 8-bit gray level range (eg 127). If necessary, the threshold level can be adjusted up or down so that the resulting torque detected will encompass the projections that appear in the acquired image with respect to its limits with the surrounding landing region.
[241] After the algorithm automatically performs several binary image processing steps on the detected binary of the projections, the analyst will have the opportunity to recheck the projection detection and correct any inaccuracies. The analyst can toggle both the 'control' and 'b' keys simultaneously to again check the projection detection against the underlying captured grayscale image. If necessary, the analyst can select from a set of binary editing tools (eg draw, reject, etc.) to make minor adjustments. If care is taken to ensure proper illumination and detection in the steps described above, little or no correction at this point should be necessary.
[242] The analyst should then turn off the Circline incident 214 fluorescent lamp and turn on the substage transmitted light bank or remove the light blocking mask. The substage transmitted light bank is adjusted by the variable autotransformer to a white level reading of approximately 0.97. At this point, the image focus can be optimized for the material landing areas.
[243] After performing the additional operations on the resulting separate binary images for projections, landing areas and open area, the algorithm will automatically perform the measurements and generate the data results in a designated EXCEL spreadsheet file. The following measurement parameter data will be located in the Excel file after measurements and data transfer are made: Landing Area Open Landing Area % of Open Landing Area Projection Area Open Projection Area % of Projection Open Area % Total open area
[244] After the data transfer, the algorithm will instruct the automatic stage 208 to move to the next field of view and the process of turning on the incident Circline fluorescent lamp 214 and blocking the transmitted light bank of substage 218 will restart. This process will be repeated four times so that there will be five datasets of five separate field of view images per individual material replica.
[245] Multiple replications of a single material can be performed during a single run of the QUIPS algorithm (Note: The To - Next line example line in the algorithm needs to be adjusted to reflect the number of material replication analyzes to be performed per material ). The final material mean diffusion value is generally based on an N=5 analysis from five individual material subsample replications. A comparison between different materials can be performed using a Student's t test, with a 90% confidence level. Method for determining the height of projections
[246] The height of the projections can be determined using the image analysis measurement method described here. The image analysis method determines a dimensional numerical height value for the projections using specific image analysis measurements from both the landing and projection areas with the underlying landing regions in a sample and then calculating the height of projection alone through the differentiation of the two. The projection height method is performed using conventional optical image analysis techniques to detect cross-sections of both landing areas and projection structures and then measures an average linear height value for each when viewed using a camera with incident lighting. The resulting measurement data is used to compare the height characteristics of different types of body-side reception input layers.
[247] Before performing image analysis measurements, the sample in question can be prepared so as to allow the visualization of a representative cross-section passing through the center of a projection. Cross sectioning can be done by securing a representative piece of the sample, on at least one of its straight edges in the cross direction of the machine, onto a flat, smooth surface with a strip of masking tape, such as % inch of a Scotch tape. ® Magic™, produced by 3M. Transverse sectioning is then performed using a new blue carbon steel (PAL) blade and carefully cutting in a direction opposite and orthogonal to the fixed edge, and through the centers of at least one projection, and preferably more if the projections are arranged in rows. in the machine direction. Any remaining rows of projections located behind the sectioned face of the projections must be cut and removed prior to assembly so that only the transversely sectioned projections remain. These cross-cut slides are available from Electron Microscopy Sciences of Hatfield, PA (Catalog No. 71974). Cross sectioning is done in the machine direction of the sample, and a new unused blade must be used for each new cross section. The cross-sectional face can now be mounted so that the projections are facing up, away from the base support, using an adhesive such as double-sided tape, so that it can be seen using a video camera with an optical lens. The bracket itself and any background behind the sample that will be seen by the camera should be darkened using a matte black tape and 317 black construction paper (shown in Figure 21), respectively. For a typical sample, enough cross sections should be cut and these should be mounted separately; From these cross sections, six projection height values can be determined.
[248] An example setup for image capture is illustrated in Figure 21. Specifically, a CCD 300 video camera (for example, a Leica DFC 310 FX video camera operated in grayscale mode and marketed by Leica Microsystems (Heerbrugg, Switzerland) is mounted on a standard 302 mount, such as a standard Polaroid MP-4 Land Camera, marketed by the Polaroid Resource Center in Cambridge, or equivalent. The 302 pattern bracket is attached to a 304 macro viewer such as a KREONITE macro viewer marketed by Dunning Photo Equipment, Inc., with a facility in Bixby, Oklahoma. An automatic stage 306 is positioned on the top surface of the macro viewer 304. The automatic stage 306 is used to move the position of a given sample for better viewing by the camera 300. A suitable automatic stage 306 is the model H112, marketed by Prior Scientific Inc., with a facility in Rockland, MA.
[249] The darkened specimen holder 308, exposing the transverse sectional face of the specimen with landing areas and projections, is placed in automatic stage 306 under the optical axis of a 50mm Nikon 310 lens with a diaphragm aperture setting of f 2.8. The Nikon 310 lens attaches to the Leica DFC 310 FX 300 camera via a 30mm extension tube 312 and a "c" mount adapter. The sample holder 308 is positioned so that the sectioned faces are aligned with the camera 300 and travel in the horizontal direction of the resulting image with the projections facing upwards opposite the base holder. The sectional face is illuminated with 316 incandescent incident light provided by two 150 watt GE Reflector Floop spotlight lamps. The two spotlight lamps are positioned to provide more illumination for the transverse face than for the sample holder 308 under it in the image. If viewed from above, directly above camera 300 and specimen cross-section holder 308, searchlight lamps 316 will be positioned approximately 30 degrees, and 150 degrees to the horizontal plane running through camera 300. From this point of view , the camera bracket will be positioned at 90 degrees. The light level of the lamps is controlled by a variable autotransformer type 3PN1010, available from Staco Energy Products Co., with unit in Dayton, OH.
[250] The image analysis software platform used to perform the measurements is a QWIN Pro (version 3.5.1) offered by Leica Microsystems, with an office in Heerbrugg, Switzerland. The system and images are also calibrated using QWIN software and a standard ruler with metric markings accurate to within a millimeter. Calibration is performed on the horizontal dimension of the video camera image. Units of millimeters per pixel are used for calibration.
[251] Thus, the method of determining the projection heights of a specimen includes the step of taking several dimensional measurements. Specifically, an image analysis algorithm is used to acquire and process images as well as perform measurements using the User Interactive Programming System (QUIPS) language Quantimet. The image analysis algorithm is reproduced below. NAME = Height - Projection vs Landing Regions - 1 PURPOSE = Measures the height of the projection and landing regions DEFINING VARIABLES AND OPENING FILES -- The following row is defined to designate where the measurement data will be stored. Open file ( C:Data39291Heightdata.xls, channel #1) FIELDS = 6 SAMPLE ID AND SETUP Insert results header File Results header (channel #1) File line ( channel #1) Measurement frame ( x 31, y 61, Width 1330, Height 978 ) Picture frame ( x 0, y 0, Width 1392, Height 1040 ) --Calvalue = 0.0083 mm/pixels CALVALUE = 0.0083 Calibrate ( CALVALUE CALUNITS$ per pixel ) To (REPLICATION = 1 for FIELDS, step 1) Clear characteristic histogram #1 Clear characteristic histogram #2 Clear Accepted IMAGE ACQUISITION AND DETECTION Pause text (" Position the sample, focus the image and set the white level to 0.95". Image Setting DC Twain [PAUSE] ( Camera 1, Auto Exposure Off, Gain 0.00, Exposure Time 200.00 ms, Brightness 0 , Lamp 49.99) Capture ( to Image0 ) ACQOUTPUT = 0 - The following line can be optionally configured to save image files to a certain location. ACQFILE$ = "C: Images39291 - for HeightText. 2H_"+STR$(REPLICATE)+"s.jpg" Write image (from ACQOUTPUT to ACQFILE$ file) Detect ( clearer than 104, from Image0 to outlined Binary0 ) IMAGE PROCESSING Fix Binary (closed from Binary0 to Binary1, cycles 4, Operator disk, edge erosion on ) Correct Torque (open from Torque1 to Torque2, cycles 4, Operator disk, edge erosion on ) Identify Torque (Fill holes from Torque2 to Torque3) Correct Torque (closed from Torque3 to Torque4, cycles 15, Operator disk, edge erosion on ) Fix Binary (open from Binary4 to Binary5, cycles 20, Operator disk, edge erosion on ) Pause text ("Fill projection and landing regions that must be included and reject detected regions" Edit Binary [PAUSE] ( Draw from Binary5 to Binary6, nib Fill, width 2) Pause text ("Select 'Landing' region for measurement". Edit Binary [PAUSE] ( Accept from Binary6 to Binary7, nib Fill, width 2) Text of pa uses ("Select 'Projection' region for measurement". Edit Binary [PAUSE] (Accept Binary6 to Binary8, nib Fill, width 2) - - Combine the landing and projection regions with the measurement grid. Graphs (Grid, 30 x 0 Lines, Grid Size 1334 x 964, Origin 21 x 21, Thickness 2, Orientation 0.000000, for Torque15 released) Binary Logic ( C = AEB: C Binary10, A Binary7, B Binary15 ) Logic binary ( C = AEB: C Binary11, A Binary8, B Binary15 ) MEASURE HEIGHTS - - Landing region only Characteristic measurement (Binary10 plane, 8 ferets, minimum area: 8, gray image: Image0) Selected parameters: X FCP, Y FCP, Feret90 Feature histogram #1 (Number Param Y, X Param Feret90, 0.0100 to 5., logarithmic, 20 boxes ) Display Feature Histogram Results (#1, Horizontal, Differentials, Boxes + graph (linear Y axis), statistics) Data Window ( 1278, 412, 323, 371 ) - Projection regions only (includes any underlying landing material) Resource measurement (Binary11 plane, 8 ferets, minimum area: 8, gray image: Image0) Selected parameters: X FCP, Y FCP, Feret90 Histogram of characteristic #2 ( Number Param Y, X Param Fere t90, 0.0100 to 10., logarithmic, 20 boxes ) Display resource histogram results (#2, horizontal, differentials, boxes + graph (linear Y axis), statistics) Data Window ( 1305, 801, 297, 371 ) GENERATE DATA File ("Landing height (mm)", channel #1) File line (channel #1) File Resource Histogram Results (#1, differentials, statistics, details of compartment, channel #1) File line (channel #1) File line (channel #1) File ("Projection height + landing (mm)", channel #1) File line (channel #1) File Resource Histogram Results (#2, differentials, statistics, compartment details, channel #1) File line (channel #1) File line (channel # º 1 ) File line (channel #1) NEXT (REPLICATION) Close file (channel #1) END
[252] The QUIPS algorithm runs with the QWIN Pro software platform. Initially, the analyst must enter the sample identification information that is sent to a designated Excel file, where the measurement data will also be sent later.
[253] The analyst should then be asked to position the sample cut mounted on automatic stage 306 with darkened background so that the transverse face is level with camera 300 with the projections facing up and the length in the horizontal plane of the live image displayed on the video monitor screen. The analyst then adjusts video camera 300 and the vertical position of lens 310 to optimize focus on the cross face. The light level is also adjusted by the analyst via the variable autotransformer for a white level reading of approximately 0.95.
[254] Once the analyst completes the above steps and executes the command to continue, an image will be acquired, detected and processed automatically by the QUIPS algorithm. The analyst should be asked to fill in the detected binary image, using the computer mouse, in any projection and/or landing areas shown in the cross-sectional image, which should have been included by the previous image detection and processing steps, as well as reject any incorrectly detected regions that go beyond the boundaries of the cross-sectional structure shown in the underlying grayscale image. To aid in this editing process, the analyst can toggle the keyboard's 'control' and 'B' keys simultaneously to turn the overlay binary image on and off to assess how closely the binary matches the sample contours shown in the cross section. If the initial cross-section sample preparation was done well, very little editing will be needed.
[255] The analyst should now "Select the 'Landing' region for measurement" using the computer mouse. This selection is accomplished by carefully drawing a vertical line across one side of a landing area located between or adjacent to the projections and then, with the left mouse button still pressed, moving the cursor under the landing area to the its opposite side, and finally, pulling the other vertical line up. Once this is done, the left mouse button can be released and the landing area to be measured should be filled with a green color. If the vertical edges of the resulting selected region are distorted in any way, the analyst can reset the detected original binary by clicking the “Undo” button located within the Binary Edit window and starting selecting again until straight vertical edges on both sides of the selected landing region are obtained.
[256] Likewise, the analyst should then "Select the 'projection' region for measurement." The upper part of a projection region adjacent to the previously selected landing area is now selected, in the same way as was previously described for a landing area selection.
[257] The algorithm will automatically perform measurements in both selected regions and generate the data in histogram format in the designated EXCEL spreadsheet file. In the Excel file, the histograms of the landing and projection regions will be labeled "Landing height (mm)" and "Landing height + projection (mm)", respectively. A separate set of histograms will be generated for each selection of landing and projection pairs.
[258] The analyst should again position the sample and begin the process of selecting different landing and projection regions. At this point, the analyst can use the automatic stage joystick to move the same cross section to a new subsampling position or an entirely different supported cross section taken from the same sample can be positioned over automatic stage 306 for measurement. The process of positioning the sample and selecting the landing and projection regions for measurement will occur six times for each execution of the QUIPS algorithm.
[259] A single projection height value is then determined by calculating the numerical difference between the mean histogram values of the landing and projection regions for each single measurement pair. The QUIPS algorithm will provide six sets of repeat measurements of both the landing and projection regions for a single sample, so that six projection height values will be generated per sample. The final sample mean diffusion value is based on an N=6 analysis of six individual subsample measurements. A comparison between different samples can be performed using Student's t-analysis with a 90% confidence level. Examples: Example 1:
[260] To demonstrate the process, equipment, and materials of this disclosure, several body-facing, fluid-entangled materials 28 were prepared as well as projection layers 94 without support layers 92. The samples were taken in one row. of spunlace production at Textor Technologies PTY LTD in Tullamarine, Australia, in a manner similar to that shown in Figure 15 of the drawings, except that a single fluid entanglement device 158c was used in forming the projections 90 in the texturing zone 178. In addition, the projection layer 94 was pre-wetted after the process shown in Figure 15 and before the fluid pre-entanglement device 158a, using conventional equipment. In this case, pre-wetting was achieved through the use of a simple injector regulated at a pressure of 8 bar. The fluid pre-entanglement device 158a was set at 45 bar, the fluid entanglement and lamination device 158b was set at 60 bar, while the pressure of the single fluid entanglement device 158c was varied as shown in Tables 1 and 2 below at pressures of 140, 160 and 180 bar, depending on the specific sample being run.
[261] For the conveyor belt 152 of Figure 15, the fluid pre-entanglement device 158a was positioned at a height of 10 mm above the conveyor belt 152. For the lamination forming surface 180, the entanglement laminating device with fluid 158b was positioned at a height of 12 mm above surface 180, as was the projection fluid entanglement device 158c with respect to the projection forming surface 156.
[262] Projection forming surface 156 was a 1.3 m wide steel texturing cylinder with a diameter of 520 mm, thickness of 3 mm and a closed hexagonal pattern of 4 mm round holes 170, spaced apart. by a spacing of 6 mm, center to center. The porous casing of inner cylinder 174 was a 100 mesh (100 threads per inch in both directions/39 threads per centimeter in both directions) of braided stainless steel. The separation or clearance between the outside of the casing 174 and the inside of the cylinder 156 was 1.5 mm.
[263] The process parameters that were varied were the aforementioned entanglement fluid pressures (140, 160 and 180 bar) and the degree of overfeed (0%, 11%, 25% and 43%) using the overfeed ratio above of OF = [(V1 / V3 ) - 1]x100 where V1 is the input velocity of the projection layer 94 and V3 is the resulting material output velocity, which is in contact with the body 28.
[264] All samples were run at the output line or the starting speed (V3) of about 25 meters per minute (m/min). V1 is reported in Tables 1 and 2 for their samples. V2 was held constant for all samples in Tables 1 and 2 at a speed equal to V3 or 25 meters per minute. Final samples were sent through an in-line dryer to remove excess water, as is common in the hydroentanglement process. The samples were collected after the dryer and then labeled with a code (see Tables 1 and 2) corresponding to the process conditions used.
[265] Regarding the materials produced, as indicated below in Tables 1 and 2, some were made with a support layer 92 and some were not, and when a support layer 92 was used, there were three variations, including a spunbond weft, a spunlace weft and an airflow bonded carded weft (TABCW). The spunbond backing layer 92 was a 17 grams per square meter (gsm) polypropylene dot-bonded weft made from 1.8 denier strength polypropylene spunbond fibers, which was then stitched together with a binding area. overall per unit area of 17.5%, produced by Kimberly-Clark Australia of Milsons Point, Australia. Spunbond material was supplied and inserted into the process in roll form, with a roll width of approximately 130 centimeters. The spunlace backing layer 92 was a 52 gsm spunlace material, with a uniform blend of 70 weight percent viscose staple fibers of 40 mm in length and 1.5 denier strength and 30 weight percent staple fibers of polyester (PET), 38mm long, 1.4 denier title, manufactured by Textor Technologies PTY LTD of Tullamarine, Australia. The spunbond material was preformed and supplied in roll form, and had a roll width of approximately 140 centimeters. The TABCW backing layer 92 had a basis weight of 40 gsm and comprised a uniform blend of 40 percent by weight of 51 mm long, 6 denier PET staple fibers and 60 percent by weight of coated bicomponent staple fibers. of polyethylene/polypropylene core, 51mm long, 3.8 denier title, manufactured by Textor Technologies PTY LTD of Tullamarine, Australia. In the data below (see Tables 1 and 2) under the heading “support layer”, the spunbond weft has been identified as “SB”, the spunlace weft has been identified as “SL” and the TABCW has been identified as “S”. Where no support layer 92 was used, the term “None” is used. The basis weights used in the examples are not to be considered as a limitation on the basis weights that can be used, as the basis weights of the support layers 92 can be varied depending on the final applications.
[266] In all cases, the projection web 94 was a carded staple web, made from 100% polyester staple fibers, 38 mm long, 1.2 denier title, available from the Huvis Corporation of Daejeon, Korea. The projection layer 94 carded web was manufactured in accordance with the hydroentanglement process of Textor Technologies PTY LTD of Tullamarine, Australia, and had a width of approximately 140 centimeters. The basis weights varied as indicated in Tables 1 and 2 and ranged from 28 gsm to 49.5 gsm, although other basis weights and ranges may be used depending on the final application. Projection layer 94 was identified as "weave card" in the data presented below, in Tables 1 and 2.
[267] The thicknesses of the materials described in Tables 1 and 2 below, as well as in Figure 22, were measured using a Mitutoyo thickness gauge model ID-C1025B with a presser foot pressure of 345Pa (0.05 psi). Measurements were taken at room temperature (about 20 degrees Celsius) and reported in millimeters using a round foot with a diameter of 76.2 mm (3 inches). The thicknesses of the selected specimens (average of three specimens) with and without support layers are shown in Figure 22 of the drawings.
[268] The tensile strength of the materials, defined as the peak load obtained during the test, was measured in both machine direction (MD) and cross machine direction (CMD) using an Instron tensile testing device model 3343 and running the Instron Series IX Rev. 1.16 software module with +/- 1kN load cell. The initial grip separation distance (“calibration length”) was set at 75 millimeters and the traction speed was 300 millimeters per minute. The samples were cut 50mm wide by 300mm long in the machine direction (MD) and each tensile strength test result reported the average of two samples per code. Samples were evaluated at room temperature (about 20 degrees Celsius). Excess material was removed from the edges and sides of the equipment. Machine direction resistances and extensions (CMD) were also measured and generally machine direction resistances (CMD) were approximately one-half to one-fifth of MD resistance and CMD extensions at full load were approximately two to three times greater than in the MD direction. (The CMD samples were cut with the long dimension in the CMD). MD forces were reported in Newtons per 50 mm of material width. (Results are in Tables 1 and 2) MD extensions of the material at maximum load were reported as a percentage of the initial gauge length (initial grip separation).
[269] Extension measurements were also made and reported on the MD at a load of 10 Newtons (N). (See Tables 1 and 2 below and Figure 23) Tables 1 and 2 show the data based on the variation of the support layer being used, the degree of supercharge being used and the variations in water pressure in the water jets of hydroentanglement.
[270] As an example of the consequences of various process parameters, high overfeed requires sufficient jet pressure to push projection layer 94 into projection forming surface 156 and also absorb excess material being overfed in the zone 178. If enough jet energy is not available to overcome the material's resistance to texturing, the material will bend and overlap and, in the worst case, may form a roll before texturing zone 178, requiring process interruption . Although the experiments were conducted at a V3 line speed of 25m/min, this should not be considered a limitation to the line speed, as equipment with similar materials was operated at line speeds ranging from 10 to 70 meters per minute and speeds outside this range can be used depending on the materials being processed.
[271] The following tables (Tables 1 and 2) summarize the materials, process parameters, and test results. The samples shown in Table 1 were made with and without support layers 92. Codes 1.1 to 3.6 used the aforementioned spunbond support layer 92. Codes 4.1 to 5.7 had no support layer 92. The jet pressures for each of the samples are listed in Tables 1 and 2.
[272] Table 1. Experimental parameters and test results, with support layer 92 and without support layer 92, codes 1 to 5.

*Note for codes 4.1 to 5.9 the “laminate” was a single layer structure as there was no backing layer 92 present.
[273] For Table 2, samples 6SL.1 to 6SL.6 were run on the same equipment, under the same conditions as the samples in Table 1 with the aforementioned spunlace support layer 92, while samples 6S.1 to 6S .4 were executed with the support layer of the weft carded by air 92. The projection layers 94 (“card wefts”) were manufactured in the same manner as those used in Table 1.Table 2. Experimental parameters and test results code 6, with alternative support layers 92.


[274] As can be seen in Tables 1 and 2, the key quality parameter of fabric thickness depends mainly on the amount of overfeed of the projection layer 94 in texturing zone 178. Regarding the data presented in Table 2, it is It is possible to see that high overfeed ratios resulted in an increase in thickness. Furthermore, at the same overfeed ratios, higher fluid pressures resulted in higher thickness values which in turn indicate an increase in overhang height 90. Table 2 shows the test results for samples made with layers of alternative brackets 92. The 6S codes used a 40 gsm air flow bonded carded web and the 6SL codes used a 52 gsm spunlace material. These materials showed good performance and good stability and appearance when compared to unsupported and unsupported specimens 92.
[275] Figure 22 illustrates the sample thickness in millimeters relative to the percentage of overfed projection layer 94 for a material facing the body 28 (represented by a diamond) compared to two samples that did not have a support layer 92 (represented by a square and a triangle). All reported values involved an average of three samples. As can be seen from the data in Figure 22, as the supercharge was increased, the sample thickness also increased, demonstrating the importance and advantage of using supercharge.
[276] Figure 23 is a graph representing the percentage of sample extension at a load of 10 Newton versus the amount of projection layer 94 supercharged for the materials in Table 1. As seen in the graph in Figure 23, when there was no backing layer 92 present, there was a drastic increase in the machine-direction extendability of the resulting sample as the percentage of material overfeed in texturing zone 178 increased. By contrast, the sample with the layer The spunbond 92 bracket experienced virtually no increase in percent extension as the overfeed ratio increased. This in turn has resulted in the projection layer 94 having projections 90 which are more stable during subsequent processing and which are better able to maintain their shape and height.
[277] As can be seen from the graph data, a higher turbocharging and therefore a higher throw height also decreased MD tensile strength and increased MD extension at full load. This was because the increased texturing provided more material (in the overhangs) that did not immediately contribute to extension strength and load generation and allowed for more extension before reaching full load.
[278] One of the main benefits of the laminate of both projection layer 94 and backing layer 92 compared to single-layer projection layer 94 without backing layer 92 may be that backing layer 92 can reduce excessive stretch during subsequent processing and converting, which can de-texture the fabric and reduce the height of projections. Without the integration of the support layer 92 into the projection formation process, it was very difficult to form the wefts with projections that could continue to be processed without the forces and stresses of the process acting on the wefts and negatively affecting the integrity of the projections, especially when low basis weight wefts were desired. Other means can be used to stabilize the material, such as thermal bonding or adhesives or increased entanglement, but these means tend to lead to a loss of softness and greater stiffness and increase the cost. The body facing material, entangled in fluid 28, can provide softness and stability at the same time. The difference between supported and unsupported textured materials is clearly illustrated in the last column of Table 1 which, for comparison purposes, shows the extent of the samples at a load of 10N. The data are also shown in Figure 23. It is possible to see that the sample supported by the spunbond support layer 92 extends only a small percentage at an applied load of 10 Newtons (N) and was almost independent of the overfeed. In contrast, the unsupported projection layer 94 extended by up to 30% at a load of 10 Newton and the extension at 10N was heavily dependent on the superfeed used to texturize the material. Low extensions at 10N can be achieved for unsupported wefts but only if there is low overfeed, which results in low throw height, ie, little texture of the weft.
[279] Figure 24 shows an example of the load-extension curves obtained in the machine direction (MD) tensile test of samples, which is the direction in which the highest loads are most likely to be experienced when traveling through the material. and in subsequent processing and conversion. All samples shown were made with an overfeed ratio of 43% and approximately the same areal density (45 gsm). It can be seen that the sample containing the spunbond support layer 92 had a much higher initial modulus, the start of the curve was sharp compared to that of the single projection layer 94 not supported by itself. This initial steeper part of the sample curve was also recoverable as the sample was elastic to the point where the gradient started to decrease. The unsupported specimen has a very low modulus, permanent deformation, and texture loss that occurs at lower load. Figure 24 shows the load-extension curves for both supported and unsupported fabric. Note the relative slope of the initial part of the curve to the supported body contacting fabric/material. This means that the unsupported specimen is relatively easily stretched and a high extension is required to generate any stress on it compared to the supported specimen. Stress is often necessary for stability in further processing and conversion, but the unsupported sample is more likely to suffer permanent deformation and loss of texture as a result of the high extension required to maintain the stress.
[280] Figures 25 and 26 show a set of curves for a wide range of conditions. It is possible to see that the samples with a low level of texturing from the low overfeed were stiffer and stronger (although a little lighter), but the lack of texture made them useless in this context. All supported laminate samples had higher starting gradients compared to unsupported ones.
[281] The level of improvement in the overall quality of the body contact material 28 when compared to a projection web 94 without backing layer 92 can be seen by comparing photographs of the materials shown in Figures 27, 27A, 28, 28A. Figures 27 and 27A are photos of the sample represented by Code 3-6 in Table 1. Figures 28 and 28A are photos of the sample represented by Code 5-3 in Table 1. These codes were selected as both had the greatest amount of supercharge (43%) and jet pressure (180 bar) using comparable spray layer 94 basis weights (38 gsm and 38.5 gsm, respectively) and therefore the highest potential for good spray formation. As can be seen by comparing the two codes and attached photos, the weft/supported laminate formed much more robust and visually perceptible projections and uniform material than the same projection layer without a support layer. They also had better properties, as shown by the data in Table 1. As a result, the supported laminate is much more suitable for further processing and use in such products as absorbent personal care articles.
[282] Figure 29 is a photograph at the interface of a projection layer 94 with and without a support layer 92. As can be seen from this photograph, the supported projection layer 94 has a much higher level of integrity. This is especially important when the material will be used in end-use applications such as absorbent personal care articles, where it is necessary (often with the use of adhesives) to secure the projection layer 94 to underlying layers of the product. With the unsupported projection layer, adhesive leakage is a much greater threat. Such leakage can result in clogging of processing equipment and undesired adhesion of layers, thereby causing excessive downtime with manufacturing equipment. In use, the unsupported projection layer 94 is more likely to allow fluids absorbed by the absorbent article (such as blood, urine, feces and menses) to flow back or "rewet" the top surface of the material, thus resulting in a inferior product.
[283] Another obvious advantage of visually observing the samples (not shown) was the coverage and degree of flatness of the backside of the first surface 96 on the outside of the support layer 92 and thus the body contact material 28 resulting from the forming process, compared to the inner surface 102 of a projection layer 94 performed by the same process 150 without a support layer 92. Without the support layer 92, the outer surface of the projection layer 94 is opposite the projections 90 it was irregular and relatively unplanar. In contrast, the same outer surface of the body-contacting material 28 in accordance with the present invention with the backing layer 92 was smoother and much flatter. Provided such flat surfaces improve the ability to adhere the body contact material 28 to other materials for further conversion. As noted in the exemplary embodiments of the products described below, when materials in contact with the body 28, in accordance with the present invention are used in items such as absorbent personal care articles, having flat surfaces, which readily interface with the adjacent layers is important in the context of joining body-contacting material 28 to other surfaces so as to allow rapid passage of body exudates through the various layers of the absorbent article. If good surface-to-surface contact between the layers is not present, fluid transfer between adjacent layers can be compromised. Examples 2 - 11
[284] In Examples 2-11 described here, the following material description table applies: Table 3: Material descriptions






Fecal material simulacrum:
[285] The following is a description of the fecal material simulacrum used in some of the examples described here. Faecal Simulator Ingredients: • Dannon® All Natural Low Fat Yogurt (1.5% fat in Grade A milk), vanilla with another natural flavor, and a 32 oz container. • McCormick ground turmeric • Great Value® 100% liquid egg whites • Genuine Knox® gelatine - unflavored and in powder form • DAWN® ultra-concentrated liquid detergent original aroma • Distilled water
[286] Note: All faecal simulant ingredients can be purchased at supermarkets such as Wal-Mart® or online retailers. Some of the faecal material simulant ingredients are perishable foods and must be incorporated into the faecal material simulacrum at least two weeks before their expiration date. Faecal material simulator mixing equipment: • Laboratory scale with 0.01 g accuracy • 500 ml beaker • Small laboratory spatula • Stopwatch • IKA®-WERKE Eurostar Power Control-Visc with R 1312 turbine mixer available together to IKA® Works, Inc., Wilmington, NC, USA.
[287] Faecal material simulant mixing procedure: 1. A 4-part mixture is created at room temperature by adding in the following order the faecal material simulant ingredients (which are at room temperature) to the beaker at a temperature between 21oC and 25oC: 57% yoghurt, 3% saffron, 39.6% egg white and 0.4% gelatin. For example, for a total mix weight of 200.0 g, the mix will have 114.0 g of yogurt, 6.0 g of saffron, 79.2 g of egg white, and 0.8 g of gelatin using the laboratory scale. 2. Mix the 4-part mixture to homogeneity using the IKA®-WERKE Eurostar mixer set at a speed of 50 RPM. Homogeneity will be achieved in about 5 minutes (using the stopwatch). The position of the beaker can be adjusted while stirring so that the entire mixture is stirred evenly. If any of the mix materials cling to the inner wall of the cup, the small spatula is used to scrape the mix material from the inner wall and place it in the center of the pan. 3. A 1.3% DAWN solution is made by adding 1.3 grams of DAWN Ultra Concentrate to 98.7 grams of distilled water. The IKA®-WERKE Eurostar and R 1312 turbine stirrer are used to mix the solution for 5 minutes at a speed of 50 RPM. 4. An amount of 2.0 grams of 1.3% DAWN solution is added to 200 grams of the 4-part mixture obtained in Step 2, for a total combined weight of 202 grams of faecal material. The 2.0 grams of 1.3% DAWN solution is stirred into the homogeneous 4-part mixture with care and only until homogeneous (approximately 2 minutes) at a speed of 50 RPM, using the IKA®-WERKE Eurostar stirrer . The final viscosity of the final fecal material simulacrum should be 390 ± 40 cP (centipoise) when measured at a shear rate of 10 s-1 and a temperature of 37oC. 5. The fecal material simulacrum is left to equilibrate for about 24 hours in the refrigerator at a temperature of 7oC. It can be stored in a closed, airtight container and refrigerated for up to 5 days at approximately 7 oC. Before use, the fecal material simulacrum must be brought into equilibrium with the ambient temperature. It should be noted that several simulated batches of faecal material of similar viscosity can be combined together. For example, five simulated batches of fecal material of similar viscosity and each 200 grams can be combined in a common container for a total volume of 1000 cc. It will take about 1 hour for the 1000 cc of faecal material to equilibrate to room temperature. Method to determine the viscosity of fecal material simulacrum:
[288] The viscosity of the fecal material simulacrum is determined using a Brookfield rheometer. The final viscosity of the final fecal material simulacrum should be 390 ± 40 cP (centipoise) when measured at a shear rate of 10 s-1 and a temperature of 37oC. Equipment: • Brookfield DV-III Model LV ULTRA Rheometer with a No. SCA-28 spindle • Rheocalc software supplied by Brookfield Method: 1. Gently invert (2 to 3 times manually, shaking slowly for approximately 5 seconds) the sealed container. simulator of faecal material before loading it into the cartridge to reduce particulate build-up at the bottom. 2. According to the instructions found in the Rheometer Operator's Manual, the faecal sham is added in an amount of 17 ml to the cartridge through a syringe and placed in the Thermosel, which is maintained at a constant temperature of 37 oC. 3. Rheocalc is programmed to run at 30 second intervals between each RPM (revolutions per minute) starting at 0.01 RPM, then 0.03, 0.07, 0.10, 0.50, 1.00, 3.00, 7.00, 10.0, 20.0, 50.0, 100.0, and 200.0 and going to 100.0, 50.0, 20.0, 7.00, 3.00 , 1.00, 0.50, 0.10, 0.07, 0.03 and 0.01. 4. Viscosity as a function of the shear rate curve can be established from Rheocalc data. From this curve it is possible to determine the viscosity at a shear rate of 10/s. 5. The test is repeated three times using three different lots of fecal material sham to establish the sham viscosity range at 10/sec. Experimental absorbent compounds:
[289] Experimental absorbent compounds are used in some of the examples described herein. What follows is a description of how experimental absorbent compounds are prepared. Materials: O Outer casing: XP-8695H Berry Plastics inner casing film, marketed by Berry Plastics, Evansville, IN, USA. The Body Contact Material, Secondary Lining, Absorbent Body, Acquisition Layer, and Fluid Transfer Layer are unique to each example and specific materials are indicated in each example as described herein. The Construction Adhesive: Available from Bostik H2525A Inc., USA The Construction Adhesive Glue Gun Nozzle: One-piece spray nozzle with a 0.012 inch orifice diameter, available as Nordson part no. 152168 Corporation, USA. Material Preparation: 1. Body Contact Material (if present in compound): Cut to a minimum size of 16 in. in length by 6.5in. width. 2. Secondary liner (if present in compound): Cut a minimum size of 16 in. in length by 6.5in. width. 3. Acquisition layer (if present on compound): Cut to a minimum size of 6in. in length by 4in. width. 4. Fluid Transfer Layer (if present on compound): Cut to a minimum size of 11.3 in. in length by 4in. width. 5. Outer Cover: Cut a minimum size of 16 in. in length by 6.5in. width.
[290] Assembly instructions for an experimental absorbent compound having a body contact material, absorbent body, and outer covering:
[291] Attach the absorbent body, centered lengthwise and widthwise, to the outer cover using 15 gsm construction adhesive to attach the absorbent body backing sheet to the outer cover.
[292] Apply 17.5 gsm of construction adhesive to the entire exposed surface of the absorbent compound constructed so far, which includes the exposed outer cover and absorbent body.
[293] Attach the body contact material, centered lengthwise and lengthwise, to the absorbent compound, which includes the outer cover and the absorbent body.
[294] Smooth out any wrinkles in the body contact material and verify that it is attached to the adhesive.
[295] Make sure all materials in the compound are glued in place by pressing firmly on the 1.5 inch perimeter.
[296] Cut out the assembled absorbent compound. The finished size should be 6 cm wide by 15.5 cm long.
[297] Mark the emission zone 6 inches from the rear edge of the absorbent body with a single, small dot using a permanent marker. The point should be placed on the transverse directional midline of the absorbent body.
[298] Assembly instructions for an experimental absorbent compound having a body contact material, fluid transfer layer, absorbent body and outer cover: 1. Attach the absorbent body, centered lengthwise and widthwise, to the outer cover using 15 gsm construction adhesive to bond the absorbent body backing sheet to the outer shell. 2. Attach the fluid transfer layer to the absorbent body using 11 gsm construction adhesive. The midline width of the fluid transfer layer should line up with the midline width of the absorbent body. 3. Apply 17.5 gsm of construction adhesive to the entire exposed surface of the so far constructed absorbent compound, which includes the exposed outer cover, absorbent body components and the fluid transfer layer. 4. Attach the body contact material, centered lengthwise and widthwise, to the absorbent compound, which includes the outer cover, absorbent body, and fluid transfer layer. 5. Follow steps 4 - 7 above for an experimental absorbent compound having a body contact material, absorbent body and outer cover.
[299] Assembly instructions for an experimental absorbent compound having a body contact material, acquisition layer, absorbent body and outer cover: 1. Attach the absorbent body, centered lengthwise and widthwise, to the outer cover using 15 gsm of construction adhesive to bond the absorbent body backing sheet to the outer shell. 2. Apply 17.5 gsm of construction adhesive to the entire exposed surface of the so far constructed absorbent compound, which includes the exposed outer cover and absorbent body. 3. Attach the acquisition layer to the body contact material using the construction adhesive. The acquisition layer and the body contacting material should be aligned on the midline of the body contacting material width. 4. Attach the body contact material and acquisition layer to the absorbent compound, which includes the outer cover and the absorbent body. 5. Follow steps 4 - 7 above for an experimental absorbent compound having a body contact material, absorbent body and outer cover.
[300] Assembly instructions for an experimental absorbent compound having a body contact material, acquisition layer, fluid transfer layer, absorbent body and outer cover: 1. Attach the absorbent body, centered in the length and width direction , to the outer cover using 15 gsm of construction adhesive to bond the absorbent body backing sheet to the outer cover. 2. Attach the fluid transfer layer to the absorbent body using 11 gsm construction adhesive. The midline width of the fluid transfer layer should line up with the midline width of the absorbent body. 3. Apply 17.5 gsm of construction adhesive to the entire exposed surface of the so far constructed absorbent compound, which includes the exposed outer cover, absorbent body components and the fluid transfer layer. 4. Attach the acquisition layer to the body contact material using the construction adhesive. The acquisition layer and the body contacting material should be aligned on the midline of the body contacting material width. 5. Attach the body contact material and acquisition layer to the absorbent compound, which includes the outer cover, absorbent body, and fluid transfer layer. The acquisition layer and fluid transfer layer should be aligned with the midline of the width of the absorbent compound. 6. Follow steps 4 - 7 above for an experimental absorbent compound having a body contact material, absorbent body and outer cover.
[301] Assembly Instructions for an Experimental Absorbent Compound having a Body Contact Material, Secondary Lining, Acquisition Layer, Fluid Transfer Layer, Absorbent Body, and Outer Cover: 1. Attach the absorbent body, centered in the direction of length and width, to the outer cover using 15 gsm of construction adhesive to bond the absorbent body backing sheet to the outer cover. 2. Attach the fluid transfer layer to the absorbent body using 11 gsm construction adhesive. The midline width of the fluid transfer layer should line up with the midline width of the absorbent body. 3. Apply 17.5 gsm of construction adhesive to the entire exposed surface of the so far constructed absorbent compound, which includes the exposed outer cover, absorbent body components and the fluid transfer layer. 4. Attach the secondary acquisition layer liner to the body contact material using the construction adhesive. The secondary liner should be aligned on the midline of the width of the body contact material. 5. Attach the acquisition layer to the secondary liner using the construction adhesive. The acquisition layer, body contact material, and secondary backing should be aligned on the midline of the body contact material width. 6. Attach the body contact material, secondary liner, and acquisition layer to the absorbent compound, which includes the outer cover, absorbent body, and fluid transfer layer. The acquisition layer and fluid transfer layer should be aligned with the midline of the width of the absorbent compound. 7. Follow steps 4 - 7 above for an experimental absorbent compound having a body contact material, absorbent body and outer cover.
[302] Assembly instructions for an experimental absorbent compound having a secondary liner, acquisition layer, fluid transfer layer, absorbent body, and outer cover: 1. Attach the absorbent body, centered lengthwise and widthwise, to the outer cover using 15 gsm construction adhesive to bond the absorbent body backing sheet to the outer shell. 2. Attach the fluid transfer layer to the absorbent body using 11 gsm construction adhesive. The midline width of the fluid transfer layer should line up with the midline width of the absorbent body. 3. Apply 17.5 gsm of construction adhesive to the entire exposed surface of the so far constructed absorbent compound, which includes the exposed outer cover, absorbent body components and the fluid transfer layer. 4. Attach the acquisition layer to the secondary liner using the construction adhesive. The acquisition layer and secondary liner should be aligned on the midline of the width of the body-contacting material. 5. Attach the secondary liner and acquisition layer to the absorbent compound, which includes the outer cover, absorbent body, and fluid transfer layer. The acquisition layer and fluid transfer layer should be aligned with the midline of the width of the absorbent compound. 6. Smooth out any wrinkles in the secondary lining and make sure it adheres to any adhesive not covered by the acquisition layer. 7. Follow steps 5 - 7 above for an experimental absorbent compound having a body contact material, absorbent body and outer cover.
[303] Surface scattering of faecal material simulacrum and surface residue of faecal material simulacrum
[304] Testing Equipment and Supplies: Injection Apparatus (an exemplary configuration is illustrated in Figures 31 and 32). • 0.01 precision scale • Electronic digital gauge (VWR International Model 62379-531) • Digital thickness gauge (Mitutoyo Type IDF-1050E, and exemplary configuration illustrated in Figure 30) • Injection machine (an exemplary configuration is illustrated in Figures 34 and 36). • Digital Cooking Timer, readable up to 1 second • Digital camera (an exemplary configuration is illustrated in Figure 33). • Ruler • Faecal material sham, as described here, used at room temperature • Scott® Paper Towels (Mega Roll choose a size) • Absorbent compounds for each absorbent compound test code as described here Equipment configuration: 1 Pre-weigh a simple paper towel which, as described below, will be used to clean the intermediate plate 244 of the injection apparatus 240 without faecal material. 2. Pre-weigh four sheets of paper towels which, as described below, will be placed on top of the absorbent composite material when the absorbent composite is transferred to the vacuum box. 3. Referring to FIG. 30, a digital thickness tester is configured to obtain a bulk measurement of an absorbent compound. The digital thickness tester includes a granite base 232 having a clamping shaft 231 where the upper surface 233 of the granite base 232 is flat and smooth. A suitable granite base 232 is a Starret granite base, model 653G (available from The L.S. Starrett Company, with offices in Athol, Massachusetts, USA) or equivalent. A clamp arm 235 is attached to clamp shaft 231 at one end 236 of clamp arm 235, and a digital thickness tester 230 is attached to clamp arm 235 at the opposite end 237. 230 is a vertically moving plunger 238. Attached to distal end 239 of plunger 238 is a circular block 234 having a diameter of 76.2 mm. Block 234 is made of acrylic and is flat and smooth on at least the bottom surface. The thickness and weight of the 234 block is configured such that the 230 digital thickness tester provides a pressure of 0.05 kPa (0.345 psi). To zero the 230 digital thickness tester, make sure the granite surface 233 is clean, free of debris, and position block 234 and plunger 238 so that the lower surface of block 234 touches the surface of granite 233. After the tester of digital thickness 230 is zeroed, lift block 234 and insert an absorbent compound between block 234 and granite surface 233. The absorbent compound must have a size dimension of at least 90 mm by 102 mm. Lower block 234 and plunger 238 such that the lower surface of block 234 just touches the surface of the absorbent compound, as illustrated in FIG. 30. A pressure of 0.05 psi (0.345 kPa) is applied to the absorbent compound when block 234 is lowered. Measure and record the volume of 5 absorbent compounds for each absorbent compound test code. Calculate an average mass for the absorbent compound test code by the average of most of the 5 absorbent compounds measured for each absorbent compound test code. 4. With reference to Figs. 31 and 32, an injection apparatus 240 is configured to deliver 10 cc of fecal material simulacrum at a rate of 15 cc per second. The injection apparatus 240 has an upper plate 242, an intermediate plate 244 and a lower plate 246. The upper plate 242 has an H1 height of 12.42 mm, the intermediate plate 244 has an H2 height of 12.2 mm, and the bottom plate has an H3 height of 12.2 mm. The top plate 242 and the bottom plate 246 each have a length L1 of 305 mm and a width W1 of 165 mm. Top plate 242 is positioned along, aligned with, and connected to bottom plate 246 through the use of four threaded rods containing plastic knobs 248 located near the corners of each top plate 242 and bottom plate 246. Located between top plate 242 and bottom plate 246, intermediate plate 244 has a length L2 of 152 mm and a width W2 of 102 mm and is suspended from the top plate 242 using four screws 250 located near the corners of the intermediate plate 244. injection apparatus 240 has a faecal sham injection tube 252 located above and positioned perpendicular to the top plate 242. The faecal sham injection tube 252 has a length of 7 inches and an inside diameter of 6.4 mm . The tube is made of Norprene® to allow the delivery of faecal sham material through the tube and over the absorbent compound. Faecal sham injection tube 252 connects to top plate 242 through a hose connection 243 0.25 inch diameter. Hose connection 243 passes through top plate 242, through a hole cut in top plate 242, and to intermediate plate 244, to provide fecal material simulacrum, through a hole cut through intermediate plate 244, to the absorbent compound that is placed over the surface of the bottom plate 246. Hose fitting 243 is threaded into the intermediate plate 244 to create a seal. The hole cut in intermediate plate 244 has a cone-shaped opening 245 with a diameter of 0.88 inches. The hose connection is manufactured by Parker with a part number 125HB-3-4 and is available from MSC Industrial Supply Company. Faecal material simulator injection tube 252 is held in place on top plate 242 of injection apparatus 240 with a pinch valve block 254 containing a solenoid pinch valve 255 which can open to allow the material simulator faecal material pass through tube 252 and close to prevent faecal material simulator from passing through tube 252. The solenoid pinch valve is a two-way normally closed valve with 24VDC. The solenoid pinch valve is available from NResearch, Inc., part number 648P012. 5. Referring to FIG. 33, a digital camera 260 operated in color mode is configured to visually record the appearance of an absorbent compound upon delivery of the fecal material simulator. The 260 digital camera is a Pixelink (Model: PL-A742) with a pixel matrix of 1280x1024 and operating at a frame rate of 10.2 Hertz in color mode. A Pentax TV 262 lens (model: C6Z1218M3-2) is attached to the Pixelink 260 camera using a mount adapter at "c". The Pentax 262 lens system allows the focus of the 262 lens to be adjusted using respective software loaded on the system's computer. The 262 camera/lens system is connected to the computer via an IEEE 1394 firewire (not shown). The 260 camera and 262 lens are attached to a 264 Bencher VP-400 camera mount. The face of the Pentax 268 lens is positioned at a distance D4 of 94 cm above the base 266 of the VP-Bencher 264 camera holder. An illuminated well of absorbent compound 270 is located at a distance D6 of 16 cm below the base 266 of the pole mount VP-400 264. Distance D7 from the front face of the Pantex 262 lens to the material is 110 cm. The 270 absorbent composite well is lit on all four sides 272 with a series of 18 Sylvania GE miniature fluorescent lamps with 8 watts of power per lamp. A 1/8" thick frosted glass diffuser plate 271 is located between the lamps and the compound 270 well. The camera 260 must be maintained at the same distance and settings for all images to eliminate variability between absorbent compounds A ruler is placed in the absorptive compound well 270 and is also captured on the absorptive compound digital image for later spatial calibration reference to determine the spread size of the faecal material simulator in the absorptive compound.Images are acquired in JPEG format. 6. Referring to Figs 34-36, a vacuum apparatus 320 is prepared. Vacuum apparatus 320 comprises a vacuum chamber 322 supported on four leg members 324. Vacuum chamber 322 includes a front wall member 326 , one rear wall member 328 and two side wall members 330 and 332. The wall elements are thick enough to withstand expected vacuum pressures (5 inches s water), and are constructed and arranged to provide a chamber having outer dimensions of 23.5 inches (59.7 cm) long, 14 inches (35.6 cm) wide and 8 inches (203 cm) deep . A vacuum pump (not shown) connects to vacuum chamber 322 through a suitable vacuum line channel in a vacuum valve 334. In addition, a suitable air purge line connects within the vacuum chamber 322 via an air bleed valve 336. A hanger unit 338 is suitably mounted to the rear wall 328 and is configured with S-shaped ends to provide a convenient resting place for supporting a latex barrier sheet 340 on a convenient position away from the top of the 320 vacuum apparatus. A suitable 338 hanger can be fabricated from a stainless steel rod 0.25 inches (0.64 cm) in diameter. The latex barrier sheet 340 is wrapped around a pin element 342 to facilitate gripping and to allow convenient movement and positioning of the latex barrier sheet 340. In the position shown, the pin element 342 is shown supported on the hanger unit 338 for positioning latex barrier sheet 340 in an open position away from the top of vacuum chamber 322. A lower edge of latex barrier sheet 340 is clamped against a trailing edge support member 344 with suitable securing means, such as lever clamps 346. Lever clamps 346 mounted to rear wall member 328 with suitable spacers 348 that provide an orientation and alignment of lever clamps 346 for the desired operation. Two support shafts 350 1.5 cm in diameter are removably mounted within the vacuum chamber 322 by means of support supports 352. Support supports 352 are generally equally spaced along front wall member 326 and rear wall member 328 and arranged in cooperating pairs. In addition, support brackets 352 are fabricated and arranged to properly position the tops of support shafts 350 flush with the top of the front, rear, and sidewall members of vacuum chamber 322. brackets 350 are positioned substantially parallel to each other and are generally in line with sidewall elements 330 and 332. In addition to trailing edge support member 344, vacuum apparatus 320 includes a front support member 354 and two backing members. side supports 356 and 358. Each side support element measures about 1 inch (2.5 cm) wide and about 1.25 inches (3.2 cm) high. The lengths of the support elements are fabricated to properly surround the periphery of the upper open edges of the vacuum chamber 322, and are positioned to protrude above the upper edges of the chamber wall elements for a distance of about 0.5 inches. . A layer of egg box material 360 is positioned on top of the support shafts 350 and the upper edges of the wall elements of the vacuum chamber 322. The egg box material extends over a substantially rectangular area measuring 23, 5 inches (59.7 cm) by 14 inches (35.6 cm) and has a depth measurement of about 0.38 inches (1.0 cm). The individual cells of the egg box structure measure about 0.5 inch square, and the thin sheet material that makes up the egg box is composed of a suitable material such as polystyrene. For example, the egg carton material may be McMaster-Carr Translucent Diffuser Panel Material, Supplies Catalog No. 1624K14 (available from McMaster-Carr Supply Company, with an office in Atlanta, GA, USA). A layer of 6 mm (0.24 inch) TEFLON mesh coated with 362 screening (available from Eagle Supply and Plastics, Inc., with an office in Appleton, WI, USA) that measures 23.5 inches (59.7 cm) ) by 14 inches (35.6 centimeters), is placed over the egg box material 360. A suitable drain line and drain valve 364 to connect the bottom plate element 366 of the vacuum chamber 322 to provide a convenient mechanism for draining liquid from the vacuum chamber 322. The various wall elements and support elements of the vacuum apparatus 320 can be composed of a moisture resistant and non-corrosive material such as polycarbonate plastic. The various mounting joints can be fixed by soldering with solvent and/or fasteners, the vacuum apparatus 320 finished assembly is manufactured to be waterproof. A 368 vacuum gauge connected through conduit 370 into vacuum chamber 322. A suitable vacuum gauge 368 is a Magnahelic differential gauge capable of measuring a vacuum of 0-50 inches of water, such as an N gauge. ° 2050C available from Dwyer Instrument Incorporated (with offices in Michigan City, Indiana, USA). Deliver fecal material simulacrum and determination of residual fecal material simulacrum: 1. Adjust the positioning of the upper plate 242 of the injection apparatus 240 in relation to the lower plate 246 of the injection apparatus 240 using height-adjustable screws 248 to raise and lower the top plate 242 of the injection apparatus 240. The top plate 242 of the injection apparatus 240 should be raised and lowered for each absorbent compound test code based on the average mass of each absorbent compound test code. As intermediate plate 244 is attached to top plate 242, raising and lowering top plate 242 will also raise and lower intermediate plate 244. Top plate 242 of injection apparatus 240 must be raised and lowered for each code absorbent compound test code, such that the distance D8 between the lower plate 256 of the intermediate plate 244 and the upper surface 258 of the lower plate 246 is equivalent to the average mass of the absorbent compound test code being evaluated. After adjusting the position of the top plate 242 to set the D8 distance, a spirit level should be placed on top of the top plate 242 to ensure the top plate 242 is level. If the top plate 242 is not level, then the height adjustable screws 248 must be adjusted to ensure the top plate 242 is level, maintaining the D8 distance. 2. Position an absorbent compound of an absorbent compound test code between the middle plate 244 and the bottom plate 246 of the injection apparatus 240. Align the absorbent compound emission zone under the faecal sham injection tubing 252. 3. Zero the digital thermometer cooking. 4. Inject 10 cc of the faecal material simulant at a rate of 15 cc/sec through the faecal material simulant injection tube 252 to apply the faecal material simulant to the absorbent compound emission zone. 5. When applying the fecal material simulacrum to the absorbent compound emission zone, start the digital cooking timer and let the absorbent compound rest for two minutes. 6. After two minutes have elapsed, lift the top plate 242 and middle plate 244 from the injection apparatus 240, carefully remove the absorbent compound from the injection apparatus 240, keeping the absorbent compound flat and without any contact with the additional surfaces of the plate intermediate 244 and top plate 242. The absorbent compound having a faecal simulacrum patch is placed into the illuminated absorbent compound well 270, in accordance with the optical axis of the Pentax 262 lens. 7. The absorbent compound is in a flat and flat configuration. any macro-wrinkles are removed by the analyst's gentle manual manipulation. The absorbent composite is oriented so that the machine direction (MD) runs in the horizontal direction of the resulting image. The absorbent compound is illuminated with fluorescent light. The lights are plugged into a standard 110 volt power source and are fully lit. Align the ruler with the absorbent compound and photograph the absorbent compound located in the absorbent compound well 270 using the digital camera 260. The ruler is placed such that it is displayed just below the absorbent compound in the image (lengthwise machine direction) . The digital image of the absorbent compound is used to determine, as described below, the area of diffusion of the fecal material simulacrum. 8. The four pre-weighed sheets of paper towel are placed over the egg carton material and the TEFLON mesh of the vacuum apparatus. The four sheets are placed with the illustrations facing down towards the vacuum chamber. The four sheets are then folded in half and then folded in half again. The absorbent compound is then placed in an inverted position on top of the four sheets of paper towel. The latex barrier sheet is then placed over the absorbent compound and the four sheets of paper towels, as well as all of the TEFLON coated screen and egg carton material, so that the dam latex barrier sheet creates a seal. , when a vacuum is drawn in the vacuum apparatus. 9. Apply vacuum pressure to the combination of absorbent compound and four sheets of pre-weighed paper towels in 5 inches (0.18 psi) of water for 1 minute. 10. After 1 minute, the latex barrier sheet is inverted and the absorbent compound and four sheets of pre-weighed paper towels are removed from the vacuum apparatus. Remove the four sheets of pre-weighed paper towels from the absorbent compound and reweigh the four sheets of pre-weighed paper towels. Determine the amount of simulated fecal material transferred to the four sheets of pre-weighed paper towels by subtracting the pre-weighed weight of four sheets of paper towels from the reweighed weight of the four sheets of paper towels. 11. Use the plain pre-weighed paper towel to remove any faecal material remaining on the intermediate plate 244 of the injector 240. Clean the intermediate plate 244 with the pre-weighed paper towel to remove any remaining faecal material and weigh the plain paper towel again. Determine the amount of faecal sham that remained on the intermediate plate 244 by subtracting the preweighed weight of the plain paper towel from the reweighed weight of the plain paper towel. 12. Determine the total amount of faecal sham residual material by adding the amount of faecal material transferred to the four sheets of pre-weighed paper towels and the amount of faecal sham remaining on the intermediate plate 244 of the injection apparatus 240. 13. Clean the intermediate plate of the injection apparatus 244 between each sham injection of faecal material. 14. Repeat the above procedure for each absorbent compound of each absorbent compound test code. Determination of the Propagation Area of the Fecal Material simulacrum:
[305] The area of propagation of a faecal simulacrum patch over a given combination of absorbent compound components can be determined using the image analysis measurement method described here. Generally, the image analysis measurement method determines a numerical dimensional area value of a smear of faecal material through a combination of specific image analysis measurement parameters. The propagation area is determined using conventional optical image analysis techniques to detect spot regions and measure such parameters as the area when viewed using a camera with incident lighting. An algorithm-controlled image analysis system can detect and measure various other dimensional properties of a simulated smear of fecal material. The resulting measurement data can be used to compare the effectiveness of different combinations of layers of the absorbent article with respect to restriction and to minimize the diffusion area of a faecal material simulant.
[306] The method of determining the faecal material simulacrum propagation area in a given absorbent compound includes the step of acquiring a digital image of the absorbent compound after an emission with faecal material simulant, as described above (see method for application of the fecal material simulacrum). After acquiring the digital image of the absorbent compound, determining the simulacrum propagation area of fecal material in a given absorbent compound includes the step of taking multiple dimensional measurements. The image analysis software platform used to perform the dimensional measurements is a QWIN Pro (version 3.5.1) offered by Leica Microsystems, with an office in Heerbrugg, Switzerland. The system and images are also accurately calibrated using QWIN software and a standard ruler with metric markings of at least as little as one millimeter, which is placed next to the sample during image acquisition. Calibration is performed on the horizontal dimension of the video camera image. Units of centimeters per pixel are used for calibration. Specifically, an image analysis algorithm is used to acquire and process digital images, as well as perform measurements using the User Interactive Programming System Quantimet language. The image analysis algorithm is reproduced below. NAME = Cover-Size - BM in Diapers - 2nd PURPOSE = To measure the coverage and size of the BM in the lining on the body side of the absorbent product ENTER SAMPLE ID and OPEN DATA FILE Pause text ("Insert name of EXCEL data file now." INPUT ( FILENAME$ ) OPENFILE$ = "C:Data36775"+FILENAME$+".xls" Open file (OPENFILE$, #CHAN channel) CALIBRATE IMAGE - Calvalue = 0, 0258 cm/px CALVALUE = 0.0258 Calibrate ( CALVALUE CALUNITS$ per pixel ) Insert results header File Results header (channel #1) File line (channel #1) REPLICATE = 0 SAMPLE = 0 ACQOUTPUT = 0 SETUP Picture frame ( x 0, y 0, Width 1280, Height 1024 ) Measure frame ( x 31, y 61, Width 1218, Height 962 ) To ( SAMPLE = 1 to 156, step 1 ) Pause text ( “Enter the title of the complete image file.” Input ( TITLE$ ) File ( TITLE$, channel #1 ) File line ( channel #1 ) ACQOUTPUT IMAGE ACQUIRE = 0 -- Comment: The following line from must be set to read from the directory where the images are located. Read image [PAUSE] (from file C:Images36775 area SetcodeA3full1.jpg into Colour0) Color Transformation (RGB to HSI, Color0 to Color0) Image Window (Automatically adjust size, Auto adjust color, no auto-lut, Fit Image to Window, No Warning before image overwrite, Do not load and save annotation with image, Do not save microscope data with image, Do not load and save reference data with image) IMAGE DETECTION AND PROCESSING Pause text ( "Choose the optimal color detection") Color detection [PAUSE] (HSI+: 134-183, 140-255, 88-255, from Color0 to Binary0) Identify Binary (EdgeFeat from Binary0 to Binary0) Fix Binary (closed from Binary0 to Binary1, cycle 8, Disk operator, edge erosion on ) Identify Binary (Fill holes from Binary1 to Binary2) Fix Binary (open from Binary2 to Binary3, cycles 8, Disk operator, edge erosion on) Pause text ("Edit and select only the regions which should be measured." Edit Binary [PAUSE] ( Accept from Binary3 to Binary4, nib Fill, width 2) RESOURCE MEASUREMENT PARAMETERS Resource measurement (Binary4 plane, 32 ferets, minimum area: 75, gray image: Cor0 ) Parameters selected: Area, X FCP, Y FCP File line (channel #1) File Resource Results (channel #1) File line (channel #1) File line (channel #1) Next (SAMPLE) Close file (channel #1) END
[307] The QUIPS algorithm runs with the QWIN Pro software platform. The analyst must enter the EXCEL output data file name. Then, you are asked to enter the test code for the absorbent compound which is sent to the EXCEL file.
[308] The analyst is now prompted to enter the title of the complete digital image file which can be obtained from the host computer's directory listing of the digital images to be analyzed. The directory containing the images is usually placed on the host computer's hard drive and can be accessed from the desktop screen via MS Windows. The title information of the image file is now automatically sent to the Excel file. Then the same title of the digital image file can also be pasted into the Read Image prompt window. Now the digital image will be read from the directory to the QWIN software screen. The digital image will show the absorbent compound and any simulated faecal material stains in color. Note that the line of code in the algorithm associated with reading the digital image must be pre-configured to read from the designated host computer's hard drive directory, which contains the files to be analyzed before running the algorithm.
[309] The analyst is now asked to "Select the best color detection", adjusting the detection threshold, if necessary, in order to obtain the optimal detection possible. The hue-saturation-intensity color detection mode is used in the Cover-Size - BM in Diapers - 2nd algorithm. Typically, only the saturation and/or intensity levels will need some adjustment to optimize detection. The algorithm's detection settings can be predetermined before analyzing a set of images using QWIN and the hue-saturation-intensity color detection mode within the QUIPS algorithm with a pair of representative images. Settings can be considered optimized when the slick is covered by the overlap detection torque in relation to its outer limits and within these limits. The degree of agreement between the overlay binary and the smear images can be checked during optimization by turning the torque on and off using the 'control' and 'B' keys.
[310] After detection and a series of automatic digital image processing steps, the analyst is asked to "Edit and select only the regions that are to be measured." This is done using the computer mouse to manually select the region of the faecal simulacrum patch to be measured. The user can toggle the "B" and "control" keys on the keyboard simultaneously to turn the overlay binary image on and off. A fit between the binary image and the fecal material simulacrum patch is considered good when the binary image matches the fecal material simulacrum patch with respect to its perimeters and regions within those perimeters.
[311] The algorithm will automatically perform the measurements and generate the data in the designated EXCEL spreadsheet file. The following measurement parameter data will be located in the Excel file after measurements and data transfer are made: Area
[312] Multiple replications of digital images of a single material or multiple materials can be performed during a single execution of the QUIPS algorithm. The final sample mean spread value is based on an N=5 analysis of five individual absorbent compounds from an absorbent compound test code. A comparison between different samples can be performed using Student's t-analysis with a 90% confidence level. Example 2:
[313] The area of propagation of the fecal material simulacrum over an absorbent compound can be measured. This measurement can provide an understanding of how well a given absorbent composite design can minimize the surface propagation of fecal material across a body-contacting surface of an absorbent composite. The propagation area, measured in cm 2 , of the faecal material simulant can be determined after an emission of 10 cc of faecal material simulant, as described herein, at 15 cc/sec.
[314] In this example, eight experimental absorbent compound test codes were evaluated for the area of propagation of the faecal material simulant on the contact surface with the body of the absorbent compound test code. Five absorbent compounds from each absorbent compound test code were assembled by hand, in accordance with Table 4 below, using the corresponding material descriptions listed in Table 3: Material Descriptions above. Each absorbent compound was subjected to application of a 10 cc emission of faecal material, as described herein, at 15 cc/sec and each absorbent compound of each absorbent compound test code was analyzed according to the Propagation Area of the fecal material sham test method described herein.Table 4: Experimental absorbent compound test codes:

[315] It should be noted that "N/A" means that for the test code of the absorbent compound in question, the particular material is not present. Thus, for example, for Absorbent Compound Test Code 1, the assembled absorbent compounds had the body contact material "A" (as described in Table 3) glued to the acquisition layer "L" (as described in Table 3) without an additional layer of material between the two components. It should be understood that the body contact material "A" would be the body contact surface of the absorbent compound test code 1. Also, as an example, the absorbent compound test code 5 is a compound absorbent assembled with the body contact material "A" (as described in Table 3) adhered to the fluid transfer layer "K" (as described in Table 3) without any additional layers between the two components. It should be understood that the body contact material "A" would be the body contact surface of the absorbent compound test code 5.
[316] With respect to assembled absorbent compounds, the body contacting material is bonded to the body contacting surface of the acquisition layer or the body contacting surface of the fluid transfer layer, depending on the test code of the absorbent compound. If present, the garment contact surface of the acquisition layer is glued to the fluid transfer layer. The fluid transfer layer is glued to the absorbent body. The absorbent body is glued to the outer cover (as described in Table 3). The absorbent composites have no waist or leg elastics and no retaining flaps.
[317] As illustrated in FIG. 37 the design of the absorbent compound has an impact on the amount of spread area of the fecal material simulacrum in an absorbent compound test code. As illustrated in FIG. 37, test codes for absorbent compounds that had an acquisition layer present as part of their design had a smaller fecal material simulacrum propagation area than test codes for absorbent compounds that did not have an acquisition layer present as part of their design. your project. As illustrated in FIG. 37, with respect to absorbent compound test codes containing an acquisition layer, the absorbent compound test codes having a body contacting material body 28 with landing areas having from about 5% to about 10% open area reduced the fecal material simulacrum propagation area more than the remaining absorbent compound test codes that also contained an acquisition layer as part of their design. Example 3:
[318] The area of propagation of the fecal material simulacrum over an absorbent compound can be measured. This measurement can provide an understanding of how well a given absorbent composite design can minimize the surface propagation of fecal material across a body-contacting surface of an absorbent composite. The propagation area, measured in cm 2 , of the faecal material simulant can be determined after an emission of 10 cc of faecal material simulant, as described herein, at 15 cc/sec.
[319] In this example, twenty experimental absorbent compound test codes were evaluated for the area of propagation of the fecal material simulacrum on the contact surface with the body of the absorbent compound test code. Five absorbent compounds from each absorbent compound test code were assembled by hand, in accordance with Table 5 below, using the corresponding material descriptions listed in Table 3: Material Descriptions above. Each absorbent compound was subjected to application of a 10 cc emission of faecal material, as described herein, at 15 cc/sec and each absorbent compound of each absorbent compound test code was analyzed according to the Propagation Area of the fecal material sham test method described herein. Table 5. Experimental absorbent compound test codes


[320] It should be noted that "N/A" means that for the test code of the absorbent compound in question, the particular material is not present. Thus, for example, for Absorbent Compound Test Code 1, the assembled absorbent compounds had the body contact material "A" (as described in Table 3) glued to the acquisition layer "F" (as described in Table 3) without an additional layer of material between the two components. It should be understood that the body contact material "A" would be the body contact surface of the absorbent compound test code 1. Also, as an example, the absorbent compound test code 5 is a compound absorbent assembled with liner "E" (as described in Table 3) glued to fluid transfer layer "F" (as described in Table 3). It should be understood that the "E" liner would be the contact surface with the body of the absorbent compound test code 5. It should also be noted that some absorbent compound test codes contained a double acquisition layer, as noted in Table 5 above.
[321] With respect to assembled absorbent compounds, the body contact material or secondary liner, depending on the absorbent compound test code, is bonded to the body contact surface of the acquisition layer. The garment-contacting surface of the acquisition layer is glued to the fluid transfer layer and the fluid transfer layer is glued to the absorbent body. The absorbent body is glued to the outer cover (as described in Table 3). The absorbent composites have no waist or leg elastics and no retaining flaps.
[322] As illustrated in FIG. 38, the design of the absorbent compound has an impact on the amount of spread area of the fecal material simulant in an absorbent compound test code. As illustrated in FIG. 38, the absorbent compound test codes with the body contact material (Material codes "A" and "C") since the body contact surface had a smaller fecal material simulacrum propagation area than the absorbent compound test codes that had the secondary backing material (Material Code "E") as the body contact surface. Example 4:
[323] The area of propagation of the fecal material simulacrum over an absorbent compound can be measured. This measurement can provide an understanding of how well a given absorbent composite design can minimize the surface propagation of fecal material across a body-contacting surface of an absorbent composite. The propagation area, measured in cm 2 , of the faecal material simulant can be determined after an emission of 10 cc of faecal material simulant, as described herein, at 15 cc/sec.
[324] In this example, six experimental absorbent compound test codes were evaluated for the area of propagation of the faecal material simulant on the contact surface with the body of the absorbent compound test code. Five absorbent compounds from each absorbent compound test code were assembled by hand, in accordance with Table 6 below, using the corresponding material descriptions listed in Table 3: Material Descriptions above. Each absorbent compound was subjected to application of a 10 cc emission of faecal material, as described herein, at 15 cc/sec and each absorbent compound of each absorbent compound test code was analyzed according to the Propagation Area of the fecal material sham test method described here.Table 6: Experimental absorbent compound test codes:


[325] It should be noted that "N/A" means that for the test code of the absorbent compound in question, the particular material is not present. Thus, for example, for absorbent compound test code 1, the assembled absorbent compounds had the body contact material "A" (as described in Table 3) glued to the acquisition layer "I" (as described in Table 3) without an additional layer of material between the two components. It should be understood that the body contact material "A" would be the body contact surface of the absorbent compound test code 1. Also, as an example, the absorbent compound test code 3 is a compound absorbent assembled with liner "E" (as described in Table 3) glued to fluid transfer layer "I" (as described in Table 3). It should be understood that the "E" liner would be the contact surface with the body of the absorbent compound test code 3.
[326] With respect to assembled absorbent compounds, the body contact material or secondary liner, depending on the absorbent compound test code, is bonded to the body contact surface of the acquisition layer. The garment-contacting surface of the acquisition layer is glued to the fluid transfer layer and the fluid transfer layer is glued to the absorbent body. The absorbent body is glued to the outer cover (as described in Table 3). The absorbent composites have no waist or leg elastics and no retaining flaps.
[327] As illustrated in FIG. 39, the design of the absorbent compound has an impact on the amount of spread area of the fecal material simulant in an absorbent compound test code. As illustrated in FIG. 39, the absorbent compound test codes with the body contact material (Material codes "A" and "C") since the body contact surface had a smaller fecal material simulacrum propagation area than the absorbent compound test codes that had the secondary backing material ( Material Code "E") as the body contact surface. Example 5:
[328] The amount of residual fecal matter on the body-contacting surface of an absorbent compound can be measured. This measurement can provide an understanding of how well a given absorbent composite design can minimize the amount of fecal material that collects on the body-contacting surface. The amount of residual fecal matter can be determined, as described herein, by measuring the weight, in grams, of the fecal material simulant that can be removed from the body-contacting surface of the absorbent compound after two minutes.
[329] In this example, eight experimental absorbent compound test codes were evaluated for the simulated amount of residual fecal material on the surface contacting the body of the absorbent compound test code. Five absorbent compounds from each absorbent compound test code were assembled manually, in accordance with Table 7 below, using the corresponding material descriptions listed in Table 3: Material Descriptions above. Each absorbent compound was subjected to application of a 10 cc emission of faecal material, as described herein, at 15 cc/sec and each absorbent compound of each absorbent compound test code was analyzed according to the test method of residual surface of the fecal material simulacrum described herein.Table 7: Experimental absorbent compound test codes:

[330] It should be noted that "N/A" means that for the test code of the absorbent compound in question, the particular material is not present. Thus, for example, for Absorbent Compound Test Code 1, the assembled absorbent compounds had the body contact material "A" (as described in Table 3) glued to the acquisition layer "L" (as described in Table 3) without any additional layer of material between the two components. It should be understood that the body contact material "A" would be the body contact surface of the absorbent compound test code 1. Also, as an example, the absorbent compound test code 5 is a compound absorbent assembled with the body contact material "A" (as described in Table 3) adhered to the fluid transfer layer "K" (as described in Table 3) without any additional layers between the two components. It should be understood that the body contact material "A" would be the body contact surface of the absorbent compound test code 5.
[331] With respect to assembled absorbent compounds, the body contacting material is bonded to the body contacting surface of the acquisition layer or the body contacting surface of the fluid transfer layer, depending on the test code of the absorbent compound. If present, the garment contact surface of the acquisition layer is glued to the fluid transfer layer. The fluid transfer layer is glued to the absorbent body. The absorbent body is glued to the outer cover (as described in Table 3). The absorbent composites have no waist or leg elastics and no retaining flaps.
[332] As illustrated in FIG. 40, the design of the absorbent compound has an impact on the simulated amount of residual fecal material on the surface of an absorbent compound test code. As illustrated in FIG. 40, the absorbent compound test codes that had an acquisition layer present as part of their design had a greater amount of fecal material simulant on the body contacting surface of the absorbent compound than the absorbent compound test codes that did they didn't have an acquisition layer present as part of their design. Example 6:
[333] The amount of residual fecal matter on the body-contacting surface of an absorbent compound can be measured. This measurement can provide an understanding of how well a given absorbent composite design can minimize the amount of fecal material that collects on the body-contacting surface. The amount of residual fecal matter can be determined, as described herein, by measuring the weight, in grams, of the fecal material simulant that can be removed from the body-contacting surface of the absorbent compound after two minutes.
[334] In this example, twelve experimental absorbent compound test codes were evaluated for the simulated amount of residual fecal material on the surface contacting the body of the absorbent compound test code. Five absorbent compounds from each absorbent compound test code were assembled by hand, in accordance with Table 8 below, using the corresponding material descriptions listed in Table 3: Material Descriptions above. Each absorbent compound was subjected to application of a 10 cc emission of faecal material, as described herein, at 15 cc/sec and each absorbent compound of each absorbent compound test code was analyzed according to the test method of residual surface of the fecal material simulacrum described herein. Table 8: Experimental absorbent compound test codes:

[335] It should be noted that "N/A" means that for the test code of the absorbent compound in question, the particular material is not present. Thus, for example, for absorbent compound test code 1, the assembled absorbent compounds had the body contact material "B" (as described in Table 3) glued to the fluid transfer layer "K" (as per described in Table 3) without any additional layer of material between the two components. It should be understood that the body contact material "B" would be the body contact surface of the absorbent compound test code 1. Also, as an example, the absorbent compound test code 7 is a compound absorbent assembled with the body contact material "B" (as described in Table 3) adhered to the absorbent body "M" (as described in Table 3) without any additional layers between the two components. It should be understood that the body contact material "B" would be the body contact surface of the absorbent compound test code 7.
[336] With respect to assembled absorbent compounds, the body contacting material is adhered to the body contacting surface of the fluid transfer layer or the body contacting surface of the absorbent body, depending on the test code of the absorbent compound. If present, the fluid transfer layer is adhered to the absorbent body. The absorbent body is glued to the outer cover (as described in Table 3). The absorbent composites have no waist or leg elastics and no retaining flaps.
[337] As illustrated in FIG. 41, the design of the absorbent compound has an impact on the simulated amount of residual fecal material on the surface of an absorbent compound test code. As illustrated in FIG. 41, the absorbent compound test codes that did not have an acquisition layer and a fluid transfer layer as part of their design had a lower amount of faecal material simulant on the body contact surface of the absorbent compound than did Absorbent compound test codes that did not have the acquisition layer present, but did have a fluid transfer layer as part of their design. Example 7:
[338] The amount of residual fecal matter on the body-contacting surface of an absorbent compound can be measured. This measurement can provide an understanding of how well a given absorbent composite design can minimize the amount of fecal material that collects on the body-contacting surface. The amount of residual fecal matter can be determined, as described herein, by measuring the weight, in grams, of the fecal material simulant that can be removed from the body-contacting surface of the absorbent compound after two minutes.
[339] In this example, four experimental absorbent compound test codes were evaluated for the simulated amount of residual fecal material on the surface contacting the body of the absorbent compound test code. Five absorbent compounds from each absorbent compound test code were assembled by hand, in accordance with Table 9 below, using the corresponding material descriptions listed in Table 3: Material Descriptions above. Each absorbent compound was subjected to application of a 10 cc emission of faecal material, as described herein, at 15 cc/sec and each absorbent compound of each absorbent compound test code was analyzed according to the test method of residual surface of the fecal material simulacrum described herein.Table 9: Experimental absorbent compound test codes:

[340] It should be noted that "N/A" means that for the test code of the absorbent compound in question, the particular material is not present. Thus, for example, for absorbent compound test code 1, the assembled absorbent compounds had the body contact material "D" (as described in Table 3) glued to the fluid transfer layer "J" (as per described in Table 3) without any additional layer of material between the two components. It should be understood that the body contact material "D" would be the body contact surface of the absorbent compound test code 1. Also, as an example, the absorbent compound test code 3 is a compound absorbent assembled with the body contact material "D" (as described in Table 3) adhered to the fluid transfer layer "M" (as described in Table 3) without any additional layers between the two components. It should be understood that the body contact material "D" would be the body contact surface of the absorbent compound test code 3.
[341] With respect to assembled absorbent compounds, the body contacting material is adhered to the body contacting surface of the fluid transfer layer. The fluid transfer layer is glued to the absorbent body. The absorbent body is glued to the outer cover (as described in Table 3). The absorbent composites have no waist or leg elastics and no retaining flaps.
[342] As illustrated in FIG. 42, the design of the absorbent compound has an impact on the simulated amount of residual fecal material on the surface of an absorbent compound test code. As illustrated in FIG. 42, absorbent compound test codes that had a fluid transfer layer composed of a tissue or hydroentangled material as part of their design had a lesser amount of residual fecal material simulacrum on the body-contacting surface. of absorbent compound than the absorbent compound test codes that had Scott paper towels or a material containing polymeric material as the fluid transfer layer as part of their design. Example 8:
[343] The amount of residual fecal matter on the body-contacting surface of an absorbent compound can be measured. This measurement can provide an understanding of how well a given absorbent composite design can minimize the amount of fecal material that collects on the body-contacting surface. The amount of residual fecal matter can be determined, as described herein, by measuring the weight, in grams, of the fecal material simulant that can be removed from the body-contacting surface of the absorbent compound after two minutes.
[344] In this example, six experimental absorbent compound test codes were evaluated for the simulated amount of residual fecal material on the surface contacting the body of the absorbent compound test code. Five absorbent compounds from each absorbent compound test code were assembled by hand, in accordance with Table 10 below, using the corresponding material descriptions listed in Table 3: Material Descriptions above. Each absorbent compound was subjected to application of a 10 cc emission of faecal material, as described herein, at 15 cc/sec and each absorbent compound of each absorbent compound test code was analyzed according to the Propagation Area of the fecal material sham test method described here.Table 10: Experimental absorbent compound test codes:

[345] It should be noted that "N/A" means that for the test code of the absorbent compound in question, the particular material is not present. Thus, for example, for absorbent compound test code 1, the assembled absorbent compounds had the body contact material "A" (as described in Table 3) glued to the acquisition layer "I" (as described in Table 3) without any additional layer of material between the two components. It should be understood that the body contact material "A" would be the body contact surface of the absorbent compound test code 1. Also, as an example, the absorbent compound test code 3 is a compound absorbent assembled with liner "E" (as described in Table 3) glued to fluid transfer layer "I" (as described in Table 3). It should be understood that the "E" liner would be the contact surface with the body of the absorbent compound test code 3.
[346] With respect to assembled absorbent compounds, the body contact material or secondary liner, depending on the absorbent compound test code, is bonded to the body contact surface of the acquisition layer. The garment-contacting surface of the acquisition layer is glued to the fluid transfer layer and the fluid transfer layer is glued to the absorbent body. The absorbent body is glued to the outer cover (as described in Table 3). The absorbent composites have no waist or leg elastics and no retaining flaps.
[347] As illustrated in FIG. 43, the design of the absorbent compound has an impact on the simulated amount of residual fecal material on the surface of an absorbent compound test code. As illustrated in FIG. 43, the absorbent compound test codes with the body contact material (Material codes "A" and "C") since the body contact surface had a smaller amount of residual fecal material simulant of the than the absorbent compound test codes that had the secondary backing material (Material Code "E") as the body contact surface. As illustrated in example 2, absorbent compound test codes 1, 2, 4, and 5 would also be expected to have a greater amount of residual fecal material simulant on the absorbent compound body contact surface than the test codes of absorbent compound. However, as illustrated in FIG. 43, absorbent compound test codes 1, 2, 4 and 5 each have an acquisition layer present in their design yet showed a smaller amount of residual fecal material simulacrum on the surface contacting the body of the test codes of absorbent compound. As illustrated in Figs. 40 and 43, if an acquisition layer is present in the absorbent compound design, the composition of the acquisition layer has an impact on the amount of simulant of residual fecal material on the body contacting surface of the absorbent compound. As illustrated in FIG. 43, an acquisition layer having smaller fiber denier may have a lesser amount of residual fecal material simulant on the body contacting surface with an absorbent compound than absorbent compounds that contain a larger fiber denier acquisition layer as part. of your project. Example 9:
[348] A one-cycle compression test can be performed to measure the compressive strength of projections on single-layer projection layers and double-layer body contact materials having a support layer and a projection layer. Using measurements of the thickness of the unsupported projection layer and the contact material with the double layer body during loading and unloading, it is possible to determine the percentage elasticity.
[349] In this example, an unsupported projection layer and two body contact materials were evaluated after their removal from the absorbent compound for the percent elasticity of the unsupported projection layer and the body contact materials with double layer. Each absorbent compound was assembled by hand in accordance with Table 11 below, using the corresponding material descriptions listed in Table 3: Material Descriptions above. Each unsupported projection layer and each double-layer body contacting material was analyzed according to the one cycle compression of one cycle of percent elasticity test method described here. Table 11. Experimental Absorbent Compound Test Codes :

[350] With respect to assembled absorbent compounds, the experimental liner is glued to the contact surface with the body of the absorbent body. The garment contact surface of the absorbent body is glued to the outer cover. The absorbent composites have no waist or leg elastics and no retaining flaps.
[351] Figure 44 illustrates the compressive stress against liner thickness curves loading and unloading of a cycle and of the unsupported projection layer and the two body contact materials tested.
[352] Percent elasticity is calculated according to the following equation:

[353] Table 12 provides a summary of the liner thicknesses at 0.483 kPa during loading and unloading and the percent elasticity of the unsupported projection layer and the two body contact materials tested.Table 12. Contact material thickness with the body (mm) at 0.483 kPa (0.07 psi) during loading and unloading and percentage elasticity


[354] As indicated in Table 12, and as illustrated in FIG. 44, the percent elasticity of an unsupported single-layer projection layer is about 69%. As further indicated in Table 12, and as further illustrated in FIG. 44, the percent elasticity of a liner, such as a projection layer that has projections, can be improved by combining a projection layer with a support layer to produce the body-contacting material. Percent Elasticity - One Cycle Compression Test Method 1. Use the "freezer off" spray to gently remove unsupported spray layer or body contact material with sprays of an absorbent compound. 2. From the unsupported projection layer or body contact material, cut a test sample of 38 mm by 25 mm. 3. Top and bottom blocks made of stainless steel are coupled to a tensile tester (model: Alliance RT/1 manufactured by MTS System Corporation, a company based in Eden Prairie, Minn., USA) 4. Top block has a diameter of 57 mm while the lower block has a diameter of 89 mm. The upper block is connected to a 100 N load cell, while the lower block is connected to the base of the tensile tester. 5. The TestWorks Version 4 software program provided by MTS is used to control the movement of the upper block and record the load and distance between the two blocks. 6. The upper block is activated to slowly move down and touch the lower block until the compression load reaches about 5000g. At this point, the distance between the two blocks is zero. 7. The upper block is then adjusted to move up (away from the lower block) until the distance between the two blocks reaches 15 mm. 8. The load reading shown in the TestWorks Version 4 software program is set to zero. 9. A test sample is placed in the center of the lower block, with the projections facing the upper block. 10. The upper block is activated to descend to the lower block and compress the test sample at a speed of 25 mm/min. The travel distance of the upper block is indicated by the load reading. This is a loading process. 11. Upon reaching 345 grams of force (about 3.5 kPa), the upper block stops moving down and returns at a speed of 25 mm/min to its initial position, where the distance between the two blocks is 15 mm. This is an offloading process. 12. The compression load and the corresponding distance between the two blocks during loading and unloading are recorded on a computer using the TestWorks Version 4 program provided by MTS. 13. Compressive load is converted to compressive stress by dividing the compressive force by the area of the test specimen. 14. The distance between the two blocks at a given compressive stress represents the thickness that under that specific compressive stress. 15. A total of three test samples are tested for each test sample code to obtain representative loading and unloading curves for each test sample code. Example 10
[355] To measure the elongation and associated collapse resistance of the projections, the percent extension under various loads of an unsupported projection layer and a double-layer body contact material can be measured.
[356] In this example, an unsupported projection layer and two body contact materials were evaluated, after their removal from an absorbent compound, for the percentage extension under various loads of the unsupported projection layer and the contact material with the body. Each absorbent compound was assembled by hand in accordance with Table 13 below, using the corresponding material descriptions listed in Table 3: Material Descriptions above. Each unsupported projection layer and each contact material with the double layer body was analyzed according to the load vs. test method. percent span described here. Table 13. Experimental Absorbent Compound Test Codes:

[357] With respect to assembled absorbent compounds, the unsupported projection layer or body-contacting material is adhered to the body-contacting surface of the absorbent body. The garment contact surface of the absorbent body is glued to the outer cover. The absorbent composites have no waist or leg elastics and no retaining flaps.
[358] Figure 45 illustrates the load (N/25 mm) versus percent extension of the unsupported projection layer and two body contact materials tested.
[359] Table 14 provides a summary of load versus percent extension of the unsupported projection layer and two body contact materials tested. Table 14. Load (N/25 mm) versus % extension at various loads

[360] As illustrated in Figure 45 and summarized in Table 14, at a given load, the percentage elongation of a double-layer body contacting material is less than that of an unsupported single-layer projection layer. This demonstrates the benefit of incorporating a support layer into a body contacting material to support the projection layer of the body contacting material. The double-layer body contacting material may have better resistance to stretching and maintaining the height of the projections of the body contacting material. Tensile Force Versus Percentage Strain Test Method 1. Use the "freeze off" spray to gently remove the unsupported projection layer or body contact material with sprays of an absorbent compound. 2. Once the unsupported projection layer or body contacting material is removed, a test sample 25mm wide by 150mm long is cut from the unsupported projection layer or body contacting material. The length direction of the test sample is the machine direction of the unsupported projection layer or body-contacting material and absorbent compound. 3. The test sample is clamped between the two jaws of the Load vs. test equipment. Percent Extension (model: Alliance RT/1 manufactured by MTS System Corporation, a company based in Eden Prairie, Minn., USA) The initial separation between the two wedges is 125 mm. 4. The upper clamp is activated to travel away from the lower clamp at a speed of 3.75 cm/min. 5. The upper jaw travels approx. 38mm before being stopped. 6. The percent extension versus load curve is recorded on a computer using TestWorks version 4 software program provided by MTS. 7. A total of 3 samples were tested for each test sample to obtain a mean curve. Example 11
[361] Absorption and rewetting of female hygiene absorbent compounds and commercially available products using simulated menstruation can be assessed as described herein.
[362] In this example, three different body contact materials and two different commercially available feminine care products were evaluated for their absorption and rewetting capabilities. Each experimental sanitary napkin absorbent compound was assembled by hand in accordance with Table 15 below, using the corresponding material descriptions listed in Table 3: Material Descriptions above. Each body contact material and absorbent compound was analyzed according to the absorption/rewetting test method described herein using menstruation simulators. With respect to assembled absorbent compounds, the body contacting material is bonded to the body contacting surface of the acquisition layer. Adhesive is applied, in a width of 1.5 to 2 inches in the center of the body contacting material, to the backing layer of the body contacting material (ie, the non-projection side of the contacting material with the body). The garment contact surface of the acquisition layer is glued to the absorbent body. Table 15: Experimental female absorbent absorbent compound test codes:

[363] Test codes 4 and 5 are material codes, Q and R respectively, as described in Table 3: Material Descriptions above. Each commercially available product was analyzed according to the absorption/rewetting test method described herein using menstruation simulators.
[364] Table 16 provides a summary of the absorption and rewetting values of the three body contact materials tested and the two commercially available products tested.Table 16: Absorption/rewetting values:

[365] As summarized in Table 16, the second absorption time is shorter and therefore faster than commercially available products. This indicates that body contact material can capture fluid faster and may decrease the likelihood of fluid leakage caused by slow fluid capture by commercially available products. Generally, soak times are improved at the expense of the amount of rewetting. In this case, while the second absorption time is faster with body contact materials, there is no increase in the amount of rewetting compared to commercial products. Preparation of the menstruation simulator:
[366] The menstrual simulator was prepared using swine blood and chicken egg whites in accordance with the following protocol published on IP.com on August 6, 2010, reference number IPCOM000198395D. This is a batch process that can produce 2.5 l to 4.0 l of fluid. The menstruation simulator can be purchased from Cocalico Biologicals, Reamstown PA. 1. Device: 1.1. Agitator and support 1.2. Flat-blade rod 3" in diameter 1.3. Reaction vessel 3 l 1.4. Plastic strainer 1.5. Preparatory centrifuge 1.6. Hematocrit centrifuge 1.7. Motorized Pipettor 2. Materials and Supplies: 2.1. Fresh Jumbo Chicken Eggs 2.2. 2.3 Defibrated swine plasma 2.4 Parafilm 2.5 Microhematocrit capillary tubes 2.6 Critoseal Sealant (Oxford Labware) 3. Protocol 3.1 Egg white collection, separation and processing 3.1.1 Using chicken eggs fresh, one at a time, remove the egg from the shell and place it in a yolk separator attached to the rim of a 250 ml cup. Allow the whites to pass through the yolk separator and into the 250 ml cup, and , then discard the yolk.Remove any chalaza from the egg white using a rounded tablespoon and transfer the white to a 600ml beaker.This process is continued until 12 eggs have been processed and collected in the 600ml beaker. 3.1.2. Transfer the whites from the 12 eggs to the plastic filter/collection container and allow the fine egg white to drain through the filter into the collection container for 10 minutes. Tilt the filter pan from side to side every 3-4 minutes during this process to facilitate drainage of the fine egg whites. Discard the fine white. 3.1.3. Place a clean collection container under the filter container containing the retained thick egg white, and using the back of a tablespoon, press the white through the filter container openings and into the collection container. 3.1.4. Place the coarse processed egg whites in a 1.5 or 2 L 3.1.5 cup. Repeat processing the 12 eggs until enough thick egg white has been collected. 3.2. Preparation of swine blood plasma 3.2.1. Pour pig blood into 750 ml plastic centrifuge buckets (maximum 500 ml in each bucket) and place the buckets in the conveyors. Centrifuge buckets must be filled in pairs. 3.2.2. Carefully balance the pairs of buckets, in their carriers, on a scale by transferring blood from one bucket to the other. Then place buckets and carriers in the centrifuge. 3.2.3. Centrifuge balanced buckets at 3500 rpm for 60 minutes at room temperature. 3.2.4. Carefully remove plasma from each bucket using a 10 ml pipette and pipette motor and place in a 1 L beaker. Keep the pipette tip at least 5 mm above the red cell concentrate layer to avoid aspirating the red cells and contaminating the plasma. 3.2.5. Alternatively, defibrinated porcine plasma may be obtained from Cocalico Biologicals, Inc. 3.2.5.1. If purchased plasma is used, place the plasma in 750 ml centrifuge buckets and balance the buckets as described above. 3.2.5.2. Centrifuge plasma at 3500 rpm for 30 minutes at room temperature. This procedure will separate the plasma from any precipitate that may be present. 3.2.5.3. Decant the clarified plasma by carefully pouring the liquid into a 1 L beaker. Preparation of pig red cell concentrate 3.2.6. Follow the procedure above for the preparation of swine blood plasma. 3.2.7. Remove the remaining plasma supernatant from each bucket containing the red cell concentrate and a thin layer of plasma using a 10 ml pipette as described above in section 4.2.4. 3.2.8. A thin layer of white blood cells (known as a "buffy coat") remains on top of the concentrated red blood cell layer. Remove this layer by aspirating it into a 3 ml Pasteur plastic pipette while running the pipette tip across the surface of the red cell layer. 3.2.9. Transfer the contents of the centrifuge buckets to a 1 L beaker and mix gently with a rubber spatula. 3.2.10. Remove a small aliquot of mixed red cell concentrate and measure the hematocrit in triplicate as described in section 5 below. 3.3. Mixture of processed egg white and blood plasma 3.3.1. Pour a volume of coarse processed egg white into a 3 L reaction vessel. This volume can be between 1000 ml and 1600 ml. 3.3.2. Pour a volume of swine blood plasma into a 3 L reaction vessel. This volume should equal 75% of the volume of coarse egg white. 3.3.3. Stir the mixture briefly (10-20 seconds) with a large rubber spatula. 3.3.4. Lower the flat 3" diameter SS stir disc into the mixture. The stir disc should be centered in the reaction vessel and 5 inches below the surface of the mixture. 3.3.5. Turn on the stirrer, adjust the stir speed to 1000 rpm, and stir the mixture for 1 hour 3.3.6 Stop the stirrer and remove the stir rod and disc 3.3.7 With a rubber spatula, remove any foam that may have formed on the surface of the mixture during stirring 3.3.8 Transfer the mixture to a 3 to 4 L beaker 3.4 Adding and mixing concentrated red blood cells 3.4.1 Measure the hematocrit of the red blood cell concentrate using the procedure described in item 5 below. 2. Calculate the amount of red blood cell concentrate to be added to the egg white/mix using one of the following equations: 3.4.2.1 If red cell concentrate is added by volume, use the following equation to calculate the volume:
3.4.2.2. If concentrated red cells are added by weight, use the following equation to calculate the volume:
3.4.3. Add the calculated amount of red blood cell concentrate to the egg white/plasma mixture and stir with a rubber spatula for 1 minute. 3.5. Filling Fenwal storage bags. 3.5.1. Cut the access tube in the Fenwal storage bags to a length of approximately 24 inches. 3.5.2. Attach the cut end of the storage bag tubing to the outlet of a large plastic cup. 3.5.3. Pour the required volume of fluid into the funnel and let the fluid fill the bag through using gravity flow. 3.5.4. Using a large syringe, remove any air bubbles from the bag. 3.5.5. Measure the hematocrit of the bag contents using the procedure outlined in section 5 below. 3.5.6. Seal the bag by tying a double knot in the tubing about 2 to 3 inches from the bag, or use Fenwal metal tube clamps and cut off excess tubing. 4. Hematocrit test: 4.1. Check that the blood or simulant to be tested is at room temperature and well mixed. 4.2. Place a small aliquot (0.1 to 0.2 ml) of the fluid to be tested in a small cup or onto a piece of Parafilm. 4.3. Pour the fluid into a hematocrit tube, leaving about 15mm of air at the top of the tube. 4.4. Hold your finger over the top of the hematocrit tube (to prevent fluid from leaking out of the tube) and seal the tube by placing the bottom of the tube on the Hemoseal base. 4.5. Place the filled and sealed tubes in the hematocrit centrifuge with the sealed end outward from the center of the centrifuge. 4.6. Centrifuge tubes for 3 minutes. 4.7. Read the hematocrit from each tube using the built-in hematocrit reader. Absorption/Rewetting Test Method
[367] The prepared absorbent compounds are laid out horizontally on the test surface. The top of the absorbent compound is then wetted with a first 2 ml flush of menstruation simulator at room temperature (24 ml/min), followed by a 2 minute, 55 second pause, followed by a 3 ml drip (0 .3 ml/min), and then a second spurt of 2 ml (24 ml/min). The menstruation simulator is administered through a 404 cannula into a 400 rate pad that is placed in the center of the genital region of the test product. The 400 rate block is made of a non-electrostatic material called Ertalyte. This material allows the simulator to pass along its surface without attracting it. The opening 402 is oval in shape and measures 60 mm long (L3) X 13 mm wide (W3), with its ends 404 consisting of semicircles 4 mm in diameter. As shown in Figure 46 and Figure 46A, cannula 404 is introduced through a small central hole 406 offset in the top of rate block 400 to allow cannula 404 to form an angle with oval opening 402 and allow fluid to be drawn out. applied through the center of the oval opening 402 of the rate block 400.
[368] The first and second absorption values are measured with a stopwatch during the first and second 2 ml stream, respectively. The timer starts when the spurt starts and is stopped when the spouting liquid is completely absorbed by the absorbent compound. Rewetting values are determined after complete penetration of the second 2 ml jet. Measured rewetting values, two pieces of absorbent paper (Verigood grade, white, 300 g/m2, 48.26 by 60.96 cm stock, 250 sheets per ream, Georgia-Pacific Corp. part number 411-01- 12, or equivalent) are placed to cover the wet absorbent compound. A foot covering the absorbent compound is reduced relative to the blotting paper to create a loading pressure of 1.0 psi for 3 minutes and the amount of fluid transferred to the blotting paper is determined gravimetrically. The pressure used in this test was shown to correlate well with the pressure applied to tampons during use.
[369] For the sake of brevity and brevity, any ranges of values set forth in this disclosure contemplate all values within the range and shall be construed as supporting claims that recite any subranges having endpoints that are whole number values within the range in specified question. In a hypothetical example, a disclosure of a range ranging from 1 to 5 should be considered to support claims in any of the following ranges: 1 to 5; 1 to 4; 1 to 3; 1 to 2; 2 to 5; 2 to 4; From 2 to 3; 3 to 5; 3 to 4; and 4 to 5.
[370] 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 dimension is intended to signify the quoted value and a functionally equivalent range around this value. For example, a dimension disclosed as "40 mm" should be interpreted as "about 40 mm".
[371] All documents cited in the Detailed Description are, in relevant part, incorporated herein by reference; citation of any document should not be construed as an admission that it is state of the art in relation to this disclosure. To the extent that any meaning or definition of a term written document conflicts with any meaning or definition of a term in a document incorporated by reference, the meaning or definition ascribed to the term in this written document shall control.
[372] While specific embodiments of the present invention have been illustrated and described, it will 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 which are within the scope of this invention.

权利要求:
Claims (19)
[0001]
1. Absorbent article (10) characterized in that it comprises: a. a body-contacting fluid matted material (28), comprising: i. a backing layer (92) comprising a plurality of fibers and a first and second surface (96, 98) opposite one another; ii. a projection layer (94) comprising a plurality of fibers and an opposite inner and outer surface (102, 104), the second surface of the support layer in contact with the inner surface of the projection layer, fibers of one of the support layers and projection layer being fluidly entangled with the fibers of the other support layer and projection layer; iii. a plurality of hollow projections (90) formed from a first plurality of the plurality of fibers in the projection layer, the plurality of hollow projections extending from the outer surface of the projection layer away from the backing layer; and iv. a landing area (116), in which the plurality of hollow projections are surrounded by the resting area; B. an outer cover (26); ç. an absorbent body (40) positioned between the material in contact with the fluid entangled body and the outer covering; d. a pickup layer (84) positioned between the material in contact with the fluid-entangible body and the absorbent body; and is. a fluid transfer layer (78) positioned between the catchment layer and the absorbent body, the fluid transfer layer comprising a polymeric material; where the spread area of the fecal material in the material in contact with the fluid matted body after the emission of the fecal material simulacrum, according to the test method of "Fecal Material Simulator Spreading Area Determination" is less than approximately 34 cm2.
[0002]
2. Absorbent article (10) according to claim 1, characterized in that the capture layer (84) comprises fibers with a denier greater than approximately 5.
[0003]
3. Absorbent article (10) according to claim 1, characterized in that the landing area (116) has an open area greater than approximately 1% in a chosen area of material in contact with the fluid matted body (28) .
[0004]
4. Absorbent article (10) according to claim 3, characterized in that the landing area (116) has an open area greater than approximately 5% in a chosen area of material in contact with the fluid matted body (28) .
[0005]
5. Absorbent article (10) according to claim 4, characterized in that the landing area (116) has an open area greater than approximately 10% in a chosen area of material in contact with the fluid matted body (28) .
[0006]
6. Absorbent article (10) according to claim 3, characterized in that the open area is due to the interstitial spacing between the fibers.
[0007]
An absorbent article (10) according to claim 1, characterized in that a second plurality of fibers from the plurality of fibers of the projection layer (94) are entangled with the support layer (92).
[0008]
An absorbent article (10) according to claim 1, characterized in that the absorbent body (40) is free of superabsorbent material.
[0009]
The absorbent article (10) of claim 1, characterized in that the absorbent body (40) comprises more than 15% superabsorbent material by weight of the absorbent body.
[0010]
An absorbent article (10) according to claim 1, characterized in that the fluid matted material in contact with the body (28) comprises less than 10% machine direction extension under a load of 2 Newtons per 25 mm of width.
[0011]
11. Absorbent article (10) according to claim 10, characterized in that the material in contact with the fluid matted body (28) comprises less than 10% machine direction extension under a load of 4 Newtons by 25 mm wide.
[0012]
12. Absorbent article (10) according to claim 11, characterized in that the material in contact with the fluid matted body (28) comprises less than 10% machine direction extension under a load of 6 Newtons by 25 mm wide.
[0013]
An absorbent article (10) according to claim 1, characterized in that the projections (90) have a height of from 1 mm to 10 mm.
[0014]
An absorbent article (10) according to claim 1, characterized in that the material in contact with the fluid matted body (28) comprises a resilience greater than 70% according to the test method "Percentage of Resilience - One Cycle of Compression”.
[0015]
15. Absorbent article (10) according to claim 1, characterized in that the area of spreading of the fecal material in the material in contact with the body matted by fluid (28) after the emission of the fecal material simulacrum, in accordance with the Test method "Determining Fecal Material Simulator Spreading Area", is less than approximately 33 cm2.
[0016]
16. Absorbent article (10) according to claim 15, characterized in that the spreading area of the fecal material in the material in contact with the body matted by fluid (28) after the emission of the fecal material simulacrum, in accordance with the test method "Determination of Spreading Area of Fecal Material Simulator", is less than approximately 32 cm2.
[0017]
17. Absorbent article (10) according to claim 16, characterized in that the area of spreading of the fecal material in the material in contact with the body matted by fluid (28) after the emission of the fecal material simulacrum, in accordance with the Test method "Determining Fecal Material Simulator Spreading Area", is less than approximately 31 cm2.
[0018]
18. Absorbent article (10) according to claim 1, characterized in that the projections (90) have an open area less than approximately 1% in a chosen area of material in contact with the fluid-entangible body (28).
[0019]
19. Absorbent article (10) according to claim 18, characterized in that the open area is due to the interstitial spacing between the fibers.

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法律状态:
2018-11-21| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-11-12| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-04-13| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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2021-07-27| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-09-14| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 30/10/2013, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US13/665,838|2012-10-31|

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US13/665,838|US9480608B2|2012-10-31|2012-10-31|Absorbent article with a fluid-entangled body facing material including a plurality of hollow projections|

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PCT/IB2013/059764|WO2014068489A1|2012-10-31|2013-10-30|Absorbent article|

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