BR112021022487B1 - ABSORBENT ARTICLE - Google Patents

Abstract

ABSORBENT ARTICLE. An absorbent article may have a topsheet layer, a backsheet layer, and an absorbent core positioned between the topsheet layer and the backsheet layer. The topsheet layer may be formed of a topsheet material having an opacity of at least 40%. The backsheet layer may be formed of a backsheet material having an opacity of less than 30%. A portion of the area of the topsheet layer is defined by openings in the topsheet layer. The opacity of the topsheet layer may make the openings visible to the wearer of the absorbent article and identify to the wearer that the absorbent article has the desired attribute of breathability. In addition, the openings may be of a minimum size such that the color of the wearer's undergarment can be visible through the openings and through the backsheet layer, thereby providing the wearer with an absorbent article having the desired criterion attribute.

Description

FUNDAMENTALS OF DISCLOSURE

[001] Products such as absorbent articles are often used to collect and retain exudate from the human body containing, for example, urine, menstruation and/or blood. Comfort, absorbency and discretion are three key product attributes and areas of interest to the product user. In particular, a user is often interested in knowing that such products will absorb significant volumes of body exudates with minimal leakage, so as to protect their underwear, outer garments or bedding from stains, and that such products will help them avoid the later embarrassment caused by such stains.

[002] A wide variety of products for absorbing body exudates are currently available in the form of feminine pads, sanitary napkins, panty liners, panty liners and incontinence devices. These products generally have an absorbent core positioned between a liquid permeable topsheet layer facing the body and a liquid impermeable backsheet layer facing the garment. The edges of the topsheet and backsheet layers are often joined at their periphery to form a seal to contain the absorbent core and body exudates received into the product through the topsheet. In use, such products are typically positioned in the crotch of an undergarment for absorption of body exudates and a garment attachment adhesive on the backsheet layer may be used to secure the product to the inner crotch of the undergarment.

[003] Due to new trends in the fashion industry toward tighter and/or translucent clothing materials, users of such conventional absorbent products desire that the absorbent product be discreet when worn. This discreetness is desirable with respect to the color of the absorbent product, so that the absorbent product is not visible through the wearer's clothing. To meet this consumer desire, manufacturers have developed products that incorporate a variety of colors to match the color of the clothing fabric. However, the number of colors available to consumers for their clothing options is very large and manufacturers are unable to keep up with the large number of color options. Manufacturers have therefore begun to design absorbent products in which the topsheet layer and the backsheet layer, and in some cases the absorbent core, are transparent so that the color of the wearer's undergarment is visible through the layers of the absorbent product and the absorbent product can therefore blend with the wearer's undergarment.

[004] However, there are some drawbacks to such absorbent product designs. In addition to having a discreet absorbent product, users of such conventional absorbent products are interested in such products demonstrating that they are breathable during use (both for skin health and physical comfort) and demonstrating the ability to contain body exudate without leakage of such body exudate from the absorbent article. Manufacturers have attempted to design a product that is breathable, for example by utilizing a nonwoven material as the backsheet layer, however, such materials have not protected against the leakage of body exudates.

[005] Therefore, there is the problem of how to provide an absorbent product that is discreet and that gives the wearer confidence that the product will be breathable and will protect against leakage of body exudates from the product. There is a need to provide an improved absorbent product, such as an absorbent article, that can provide the desired attributes of discreetness, breathability, and protection against leakage of body exudates to the wearer of the absorbent article.

DISCLOSURE SUMMARY

[006] In various embodiments, an absorbent article may have a perimeter defined by a first transverse direction end edge and a second transverse direction end edge opposite the first transverse direction end edge, and an opposing pair of longitudinal direction side edges extending between and connecting the first transverse direction end edge and the second transverse direction end edge; a topsheet layer that may have a topsheet material having an opacity of at least 40%, a body-facing surface, and an absorbent core-facing surface; an area defined by the perimeter of the absorbent article; a plurality of apertures extending from the body-facing surface of the topsheet material to the absorbent core-facing surface of the topsheet material, each aperture providing an open space within the area of the topsheet layer; a backsheet layer comprising a backsheet material having an opacity of less than 30%; and an absorbent core positioned between the topsheet layer and the backsheet layer.

[007] In various embodiments, the opacity of the topsheet layer material is at least 45%. In various embodiments, the opacity of the backsheet layer material is less than 25%. In various embodiments, an opacity of the absorbent core is at least equal to the opacity of the topsheet layer material. In various embodiments, an opacity of the absorbent core is greater than the opacity of the topsheet layer material.

[008] In various embodiments, a size dimension of the absorbent core is 15% to 60% of a size dimension of the absorbent article.

[009] In various embodiments, the area of the top sheet layer contains from 15% to 40% open space. In various embodiments, each aperture of the plurality of apertures has a size dimension greater than 0.3 mm2. In various embodiments, each aperture of the plurality of apertures has a size dimension greater than 0.7 mm2.

[0010] In various embodiments, the absorbent article may further have a secondary absorbent layer. In various embodiments, the secondary absorbent layer is positioned between the absorbent core and the backsheet layer. In various embodiments, the secondary absorbent layer has an opacity of less than 30%. In various embodiments, the secondary absorbent layer has an opacity of less than 25%.

BRIEF DESCRIPTION OF THE FIGURES

[0011] FIG. 1 is a top-down view of one embodiment of an absorbent article.

[0012] FIG. 2 is an enlarged side view of an embodiment of the absorbent article of FIG. 1.

[0013] FIG. 3 is an enlarged front view of the absorbent article of FIG. 2.

[0014] FIG. 4 is an enlarged side view of another embodiment of the absorbent article of FIG. 1.

[0015] FIG. 5 is an enlarged front view of the absorbent article of FIG. 4.

[0016] FIG. 6 is a top-down view of another embodiment of an absorbent article.

[0017] FIG. 7 is an enlarged side view of an embodiment of the absorbent article of FIG. 6.

[0018] FIG. 8 is an enlarged side view of another embodiment of the absorbent article of FIG. 6.

[0019] The repeated use of reference characters in this descriptive report and in the figures is intended to represent the same or analogous characteristics or elements of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0020] The present disclosure is generally directed to an absorbent article that can provide both discretion and breathability. The absorbent article can have a topsheet layer, a backsheet layer, and an absorbent core positioned between the topsheet layer and the backsheet layer. The topsheet layer can be formed of a topsheet material having an opacity of at least 40%. The backsheet layer can be formed of a backsheet material having an opacity of less than 30%. A portion of the area of the topsheet layer is defined by openings in the topsheet layer. The opacity of the topsheet layer can make the openings in the topsheet layer visible to the wearer of the absorbent article, identifying to the wearer of the absorbent article that the absorbent article has the desired attribute of breathability. Furthermore, the openings within the topsheet layer can be of a minimal size such that the color of the wearer's undergarment can be visible through the openings in the topsheet layer and through the backsheet layer, thereby providing the wearer with an absorbent article having the desired discretion attribute.

Definitions:

[0021] As used herein, the term "absorbent article" refers herein to a garment or other absorbent personal hygiene article of end use, including, but not limited to, catamenial products such as feminine pads, panty liners, sanitary napkins, incontinence devices, and the like.

[0022] As used herein, the term "air-deposited" refers herein to a web manufactured by an air-lay process. In the air-lay process, bundles of small fibers having typical lengths ranging from about 3 to about 52 mm are separated and contained in a supply of air, and then deposited onto a forming screen, generally with the assistance of a vacuum supply. The randomly deposited fibers are then bonded together using, for example, hot air to activate a binder component or a latex adhesive. Air-lay is disclosed, for example, in U.S. Pat. No. 4,640,810 to Laursen et al., which is incorporated herein by reference in its entirety for all purposes.

[0023] As used herein, the term "bonded" refers herein to joining, adhering, connecting, fixing, or the like, two elements. Two elements shall be considered bonded when they are joined, adhered, connected, fixed, or the like, directly or indirectly to each other, for example, when bonded to an intermediate element. Bonding may occur by adhesives, pressure bonding, thermal bonding, ultrasonic bonding, joining, sewing, suturing, and/or welding.

[0024] As used herein, the term "bonded carded web" refers herein to webs that have been made from staple fibers that are sent through a combing or carding unit that separates or breaks and aligns the staple fibers in the machine direction to form a fibrous nonwoven web generally oriented in the machine direction. This material may be bonded by methods that may include spot bonding, airflow bonding, ultrasonic bonding, adhesive bonding, etc.

[0025] As used herein, the term "coformed" generally refers herein to composite materials comprising a mixture or stabilized matrix of thermoplastic fibers and a second non-thermoplastic material. As an example, coformed materials can be manufactured by a process in which at least one melt blowing die head is disposed near a trough through which other materials are added to the web while forming. Such other materials can include, but are not limited to, fibrous organic materials such as wood pulp or non-wood pulp such as cotton, rayon, recycled paper, pulp lint, and also superabsorbent particles, inorganic and/or organic absorbent materials, treated polymeric discontinuous fibers, and so on. Some examples of such coformed materials are disclosed in Patent Nos. 4,100,324 to Anderson, et al., 4,818,464 to Lau, 5,284,703 to Everhart, et al. and 5,350,624 to Georger, et al., each of which is incorporated herein in its entirety by reference thereto for all purposes.

[0026] As used herein, the term "conjugate fibers" refers herein to fibers that have been formed from at least two polymer sources extruded from separate extruders but spun together to form a fiber. Conjugated fibers are also sometimes referred to as bicomponent fibers, or multicomponent fibers. The polymers are arranged in substantially distinct zones constantly positioned throughout the cross sections of the conjugate fibers and extend continuously along the length of the conjugate fibers. The configuration of such a conjugate fiber may be, for example, a sheath/core arrangement in which one polymer is surrounded by another, or may be in a side-by-side configuration, or in an "islands in a sea" configuration. Conjugated fibers are disclosed by U.S. Patent Nos. 5,108,820 to Kaneko, et al., 4,795,668 to Krueger, et al., 5,540,992 to Marcher, et al., 5,336,552 to Strack, et al., 5,425,987 to Shawver, and 5,382,400 to Pike, et al., each of which is incorporated herein in its entirety by reference thereto for all purposes. For bicomponent fibers, the polymers may be present in proportions of 75/25, 50/50, 25/75, or any other desired proportion. In addition, polymeric additives, such as processing aids, may be included in each zone.

[0027] As used herein, the term "hydrophilic" refers to surfaces with a water contact angle equal to or less than 59°.

[0028] As used herein, the term "hydrophobic" refers to surfaces with the property of repelling fluid with a water contact angle equal to or greater than 90°.

[0029] As used herein, the term "semi-hydrophilic" refers to surfaces with a water contact angle of 60° to 89°.

[0030] The term "machine direction" (MD) refers to the length of a fabric in the direction in which it is produced, as opposed to "counter machine direction" (CD), which refers to the width of a fabric in a direction generally perpendicular to the machine direction.

[0031] As used herein, the term "meltblown web" refers herein to a nonwoven web that is formed by a process in which a molten thermoplastic material is extruded through a plurality of fine, generally circular, matrix capillaries as molten fibers into converging streams of gas (e.g., air) at high velocity that attenuate the fibers of the molten thermoplastic material to reduce their diameter, which may be microfiber diameter. Thereafter, the molten fibers are carried by the high velocity gas stream and are deposited on a collection surface to form a web of randomly distributed meltblown fibers. Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 to Butin et al., which is incorporated herein in its entirety by reference for all purposes. Generally speaking, meltblown fibers can be microfibers that are substantially continuous or discontinuous, generally smaller than 10 microns in diameter, and generally adherent when deposited on a collection surface.

[0032] As used herein, the term "nonwoven fabric or web" refers to a web having a structure of individual fibers or segments that are interwoven but not identifiably as a knitted fabric. Nonwoven fabrics or webs have been formed from many processes such as meltblown processes, spinbonded processes, air-bonded carded web processes (also known as BCW and TABCW), etc. The basis weight of nonwoven webs can generally vary as well from about 5, 10 or 20 g/m2 to about 120, 125 or 150 g/m2.

[0033] As used herein, the term "opacity" refers herein to the ability of a material to block the transmission of visible light through the body of the material. Opacity can be measured using a standard colorimeter. The closer an opacity measurement is to 100%, the more opaque the material.

[0034] As used herein, the term "spunbond web" refers herein to a web containing continuous fibers of substantially small diameter. The fibers are formed by extruding a molten thermoplastic material from a plurality of fine, generally circular, capillaries of a spinneret with the diameter of the extruded fibers then being rapidly reduced by, for example, draw extrusion and/or other well-known spunbond making mechanisms. The production of spinbound webs is described and illustrated, for example, in U.S. Patent Nos. 4,340,563 to Appel, et al., 3,692,618 to Dorschner, et al., 3,802,817 to Matsuki, et.al., 3,338,992 to Kinney, 3,341,394 to Kinney, 3,502,763 to Hartman, 3,502,538 to Levy, 3,542,615 to Dobo, et al., and 5,382,400 to Pike, et al., which are each incorporated in their entirety herein by reference for all purposes. Spunbond fibers are generally non-sticky when deposited on a collecting surface. Spinbound fibers can sometimes have diameters of less than about 40 microns and often between about 5 to about 20 microns.

[0035] As used herein, the terms "superabsorbent polymer," "superabsorbent," or "SAP" are to be used interchangeably and are to mean polymers that can absorb and retain extremely large amounts of a liquid relative to their own mass. Water-absorbing polymers, which are classified as hydrogels, which can be crosslinked, absorb aqueous solutions through hydrogen bonding and other polar forces with water molecules. The ability of a SAP to absorb water is based in part on the ionicity (a factor of the ionic strength of the aqueous solution) and the polar functional groups of the SAP that have an affinity for water. SAPs are typically made from the polymerization of acrylic acid mixed with sodium hydroxide in the presence of an initiator to form a sodium salt of polyacrylic acid (sometimes referred to as sodium polyacrylate). Other materials are also used to produce a superabsorbent polymer, such as polyacrylamide copolymer, ethylene maleic anhydride copolymer, cross-linked carboxymethyl cellulose, polyvinyl alcohol copolymers, cross-linked polyethylene oxide, and polyacrylonitrile starch graft copolymer. SAPs may be present in the absorbent articles in particulate or fibrous form, or as a coating on another material or fiber.

Absorbent article:

[0036] The present disclosure is generally directed to an absorbent article that can provide both discretion and breathability. The absorbent article can have a topsheet layer, a backsheet layer, and an absorbent core positioned between the topsheet layer and the backsheet layer. The topsheet layer can be formed of a topsheet material having an opacity of at least 40%. The backsheet layer can be formed of a backsheet material having an opacity of less than 30%. A portion of the area of the topsheet layer is defined by openings in the topsheet layer. The opacity of the topsheet layer can make the openings in the topsheet layer visible to the wearer of the absorbent article, identifying to the wearer of the absorbent article that the absorbent article has the desired attribute of breathability. Furthermore, the openings within the topsheet layer can be of a minimal size such that the color of the wearer's undergarment can be visible through the openings in the topsheet layer and through the backsheet layer, thereby providing the wearer with an absorbent article having the desired discretion attribute.

[0037] Referring to FIGS. 1-3, FIG. 1 provides an illustration of a top-down view of an exemplary absorbent article 10, FIG. 2 provides an illustration of an enlarged side view of the absorbent article 10 of FIG. 1, and FIG. 3 provides an illustration of an enlarged front view of the absorbent article 10 of FIG. 2. The absorbent article 10 may have a longitudinal direction (X), a transverse direction (Y), and a depth direction (Z). The absorbent article 10 may have a first transverse direction end edge 12, a second transverse direction end edge 14 opposite the first transverse direction end edge 12, and a pair of opposing longitudinal direction side edges, 16 and 18, extending between and connecting the first transverse direction end edge 12 and the second transverse direction end edge 14. In various embodiments, the absorbent article 10 may assume various geometries, but will generally have a pair of opposing transverse direction end edges, 12 and 14, and a pair of opposing longitudinal direction side edges, 16 and 18. Each of the edges, 12, 14, 16, and 18, forms the overall perimeter 20 of the absorbent article 10 defining the overall shape of the absorbent article 10. The absorbent article 10 may have a user-facing liquid-permeable topsheet layer 30 and a user-facing liquid-impermeable backsheet layer 30. the garment 40. An absorbent core 50 may be positioned between the topsheet layer 30 and the backsheet layer 40. The perimeter 20, in addition to defining the general geometry of the absorbent article 10, may also define the general shape of each of the topsheet layer 30 and the backsheet layer 40.

[0038] The topsheet layer 30 and the backsheet layer 40 may extend beyond the outermost peripheral edges of the absorbent core 50 and may be peripherally bonded, in whole or in part, using known bonding techniques to form a sealed peripheral region. For example, the topsheet layer 30 and the backsheet layer 40 may be joined by gluing, ultrasonic bonding, or any other suitable bonding method known in the art.

Top sheet layer:

[0039] The topsheet layer 30 defines a body-facing surface 32 of the absorbent article 10 that can directly contact the body of the wearer and is liquid-permeable to receive bodily exudates. Opposite the body-facing surface 32 of the topsheet layer 30 is the absorbent core-facing surface 34 of the topsheet layer 30 that faces the absorbent core 50 of the absorbent article 10. The topsheet layer 30 is desirably proportioned for comfort and functions to direct bodily exudates away from the body of the wearer, through its own structure, and toward the absorbent core 50. The topsheet layer 30 desirably retains little or no liquid in its structure, so that it provides a relatively comfortable and non-irritating surface next to the skin of a wearer of the absorbent article 10.

[0040] The topsheet layer 30 may be formed from a topsheet material 36, wherein the topsheet material 36 may be a single layer of material or, alternatively, may be multiple layers that have been laminated together. The topsheet material 36 of the topsheet layer 30 may be constructed of any material, such as one or more woven sheets, one or more nonwoven fibrous sheets, one or more film sheets, such as blown or extruded films, which may themselves be single or multilayer, one or more foam sheets, such as crosslinked, open-cell or closed-cell foams, a coated nonwoven sheet, or a combination of any of these materials. Such a combination may be adhesively, thermally, or ultrasonically laminated into a unified flat sheet structure to form the topsheet material 36 of the topsheet layer 30.

[0041] In various embodiments, the topsheet material 36 of the topsheet layer 30 may be constructed from various nonwoven webs, such as meltblown webs, spunbond webs, hydroentangled spunlace webs, or through air-bonded carded webs. Examples of suitable materials for the topsheet material 36 for the topsheet layer 30 may include, but are not limited to, natural fiber webs (such as cotton), rayon, hydroentangled webs, bonded carded webs of polyester, polypropylene, polyethylene, nylon, or other heat-bondable fibers (such as bicomponent fibers), polyolefins, polypropylene and polyethylene copolymers, linear low-density polyethylene, and aliphatic esters such as polylactic acid. Finely perforated films and web materials may also be used, as laminates of and/or combinations of these materials. An example of a topsheet layer material 36 suitable for a topsheet layer 30 is a natural fiber batt formed from 100% cotton. An additional example of a suitable topsheet layer 30 is one formed from a topsheet material 36 that is a bonded carded batt made of polypropylene and polyethylene, such as that available from Sandler Corp., Germany. U.S. Patent Nos. 4,801,494 to Datta, et al., and 4,908,026 to Sukiennik, et al., and WO 2009/062998 to Texol, teach various other topsheet materials 36 that may be used as the topsheet layer 30, each of which is incorporated herein by reference hereto in its entirety. Additional topsheet materials 36 for a topsheet layer 40 may include, but are not limited to, those described in U.S. Pat. Nos. 4,397,644 to Matthews, et al., 4,629,643 to Curro, et al., 5,188,625 to Van Iten, et al., 5,382,400 to Pike, et al., 5,533,991 to Kirby, et al., 6,410,823 to Daley, et al., and U.S. Publication No. 2012/0289917 to Abuto, et al., each of which is incorporated herein by reference in its entirety.

[0042] In various embodiments, the topsheet layer 30 may contain a plurality of apertures 60. Each aperture 60 may extend from the body-facing surface 32 of the topsheet layer 30 to the absorbent core-facing surface 34 of the topsheet layer 30 to allow body exudates to more readily pass into the absorbent core 50. The apertures 60 may be arranged randomly or uniformly throughout the topsheet layer 30. Each aperture 60 may be in the shape of a circle, oval, square, rectangle, diamond, or any other geometric shape deemed suitable. Each opening 60 may be bounded by a perimeter 62 that defines the size of each opening 60 and therefore the amount of open space within the upper sheet layer 30 due to the presence of the opening 60. The size of each opening 60 is at least 0.3, 0.5, 0.7, 1.0, 1.2, 1.4, 1.8, 2.0, 2.2, 2.4, 2.6, 2.8, 3.0, or 3.2 mm2. The perimeter 20 of the absorbent article 10 may define the area of the topsheet layer 30. In various embodiments, the number of apertures 60 present in the topsheet layer 30 in combination with the size of each aperture 60 in the topsheet layer 30 may result in the area of the topsheet layer 30 containing from 15, 20, or 25% to 30, 35, or 40% open space due to the presence of the plurality of apertures 60.

[0043] In various embodiments, the top sheet layer material 36 forming the top sheet layer 30 may have an opacity of at least 40%. In various embodiments, the top sheet layer material 36 forming the top sheet layer 30 may have an opacity of at least 45%. The opacity of the top sheet layer material 36 forming the top sheet layer 30 is measured prior to incorporating any apertures 60 into the top sheet layer 30. The opacity of the top sheet material 36 forming the top sheet layer 30 in combination with the size of the apertures 60 may visually highlight the presence of the apertures 60 within the top sheet layer 30.

[0044] In various embodiments, topsheet layer 30 can have a basis weight ranging from about 5, 10, 15, 20, or 25 g/m2 to about 50, 100, 120, 125, or 150 g/m2. For example, in one embodiment, topsheet layer 30 can be constructed from an air-bonded carded web having a basis weight ranging from about 15 g/m2 to about 100 g/m2. In another example, topsheet layer 30 can be constructed from an air-bonded carded web having a basis weight of about 20 g/m2 to about 50 g/m2, as well as an air-bonded carded web that is readily available from nonwoven manufacturers such as Xiamen Yanjan Industry, Beijing DaYuan Nonwoven Fabrics, and others. Alternatively, apertured films, such as those available from film suppliers such as Texol, Italy and Tredegar, USA, may be employed. In various embodiments, the topsheet layer 30 may be constructed from a perforated polyethylene film having a basis weight of from about 15 g/m2 to about 30 g/m2. In various embodiments, the topsheet layer 30 may be constructed from a cotton material and have a basis weight of from about 25 g/m2 to about 35 g/m2.

[0045] In various embodiments, the topsheet layer 30 may be at least partially hydrophilic. In various embodiments, a portion of the topsheet layer 30 may be hydrophilic and a portion of the topsheet layer 30 may be hydrophobic. In various embodiments, the portions of the topsheet layer 30 that may be hydrophobic may be an inherently hydrophobic material, or may be a material treated with a hydrophobic coating.

Absorbent Core:

[0046] An absorbent core 50 may be positioned between the topsheet layer 30 and the backsheet layer 40. The absorbent core 50 is designed to absorb bodily exudates, including menstrual fluid, blood, urine, and other bodily fluids such as sweat and vaginal secretions.

[0047] The absorbent core 50 may generally be any single layer structure or combination of layer components, which may demonstrate some level of compressibility, conformability, be non-irritating to the wearer's skin, and capable of absorbing and retaining fluids and other bodily exudates. In various embodiments, the absorbent core 50 may be formed from a variety of different materials and may contain any number of desired layers. In various embodiments in which the absorbent core 50 is a multilayer structure, each of the layers may contain similar materials or different materials. For example, the absorbent core 50 may include one or more layers (e.g., two layers) of absorbent web material of cellulosic fibers (e.g., wood pulp fibers), other natural fibers, synthetic fibers, woven or nonwoven sheets, cotton webs or other stabilizing structures, superabsorbent materials, binder materials, surfactants, selected hydrophobic and hydrophilic materials, pigments, lotions, odor control agents, or the like, as well as combinations of these materials. In one embodiment, the absorbent web material may include a cellulosic fluff matrix and may also include superabsorbent materials. The cellulosic fluff may comprise a blend of cellulose fluff. An example of cellulose fluff may be identified by the trade name NB 416, available from Weyerhaeuser Corp., and is a highly absorbent bleached wood pulp containing primarily softwood fibers. By way of example, suitable materials and/or structures for absorbent core 52 may include, but are not limited to, those described in U.S. Patent Nos. 4,610,678 to Weisman et al., 6,060,636 to Yahiaoui et al., 6,610,903 to Latimer et al., 7,358,282 to Krueger et al., and U.S. Publication No. 2010/0174260 to Di Luccio et al., each of which is incorporated herein by reference in its entirety.

[0048] In various embodiments, if desired, the absorbent core 50 may include an optional amount of superabsorbent material. Examples of suitable superabsorbent materials may include poly(acrylic acid) and poly(methacrylic acid), poly(acrylamide), poly(vinyl ethers), copolymers of maleic anhydride with vinyl ethers and α-olefins, poly(vinyl pyrrolidone), poly(vinylmorpholinone), poly(vinyl alcohol), and their salts and copolymers. Other superabsorbent materials may include unmodified and modified natural polymers such as acrylonitrile-grafted hydrolyzed starch, acrylic acid-grafted starch, methylcellulose, chitosan, carboxymethyl cellulose, hydroxypropyl cellulose, and natural gums such as alginates, xanthan gum, locust bean gum, and so on. Blends of natural and synthetic superabsorbent polymers, in whole or in part, may also be useful. The superabsorbent material may be present in the absorbent core 50 in any desired amount.

[0049] Regardless of the combination of absorbent materials used in the absorbent core 50, the absorbent materials may be formed into a web structure using a variety of conventional methods and techniques. For example, the absorbent web may be formed by techniques such as, but not limited to, dry forming technique, air flow forming technique, wet forming technique, foam forming technique, and the like, as well as combinations thereof. A co-formed nonwoven material may also be employed. Methods and apparatus for performing such techniques are well known in the art.

[0050] The absorbent core 50 may have a first transverse direction core end edge 52, as well as a second transverse direction core end edge 54 opposite the first transverse direction core end edge 52. The absorbent core 50 may also have a pair of opposing longitudinal direction core side edges, 56 and 58. The combination of each of the transverse direction core end edges, 52 and 54, and the longitudinal direction core side edges, 56 and 58, provides an overall shape and size dimension of the absorbent core 50. The absorbent core 50 may be provided in any shape deemed suitable for the absorbent article 10, such as, but not limited to, circular, oblong, oval, rectangular, teardrop, hourglass, racetrack, triangular, bone, and elliptical. In various embodiments, the shape of the absorbent core 50 can have a shape that provides symmetry about at least one axis, longitudinal and/or transverse, of the absorbent article 10. In various embodiments, the shape of the absorbent core 50 can be one in which there is no symmetry of the absorbent core 50 with respect to any of the axes, longitudinal or transverse, of the absorbent article 10. The size dimension of the absorbent core 50 can be smaller than the size of the overall absorbent article 10 in order to be adequately contained therein. In various embodiments, the size dimension of the absorbent core 50 is 15, 20, 25, or 30% to 35, 40, 45, 50, 55, or 60% of the size of the absorbent article 10, wherein the size dimension of the absorbent article 10 is defined by the perimeter 20 of the absorbent article 10. In various embodiments, as illustrated in FIGs. 1-5 , the absorbent core 50 may have a generally ovular shape and may be centered within the absorbent article 10. As illustrated in FIGS. 1-5 , the absorbent core 50 may have a size dimension that is approximately 20% of the size dimension of the absorbent article 10. In various embodiments, as illustrated in FIGS. 6-8 , the absorbent core 50 may have an elongated rectangular shape and may extend from a portion of the first transverse directing edge 12 to a portion of the second transverse directing edge 14 of the absorbent article 10. As illustrated in FIGS. 6-8 , the absorbent core 50 may have a size dimension that is approximately 50% of the size dimension of the absorbent article 10.

[0051] As described above, in various embodiments, an absorbent core 50 can be a single layer structure and can include, for example, a matrix of cellulose fluff and superabsorbent material. In various embodiments, an absorbent core 50 can have at least two layers of material, such as, for example, a body-facing layer and a garment-facing layer. In various embodiments, the two layers can be identical to one another. In various embodiments, the two layers can be different from one another. In such embodiments, the two layers can provide the absorbent article with different wicking properties, as deemed appropriate. In various embodiments, the body-facing layer of the absorbent core 50 can be constructed of air-bonded carded batt material and the garment-facing layer of the absorbent core 50 can be constructed of a compressed sheet of cellulosic pulp. In such embodiments, the air-bonded carded web material may have a basis weight of about 20 to about 30 g/m2 and the compressed sheet of cellulosic pulp may have a basis weight of about 80 to about 120 g/m2.

[0052] In various embodiments, the absorbent core 50 can have an opacity that is the same as the opacity of the topsheet material 36 forming the topsheet layer 30. In various embodiments, the absorbent core 50 can have an opacity that is greater than the opacity of the topsheet material 36 forming the topsheet layer 30. In various embodiments, the absorbent core 50 can have an opacity of at least 40%. In various embodiments, the absorbent core 50 can have an opacity of at least 45%.

Secondary Absorbent Layer:

[0053] In various embodiments, an absorbent article 10 may have an additional layer in the absorbent article 10 that may be a secondary absorbent layer 70. A secondary absorbent layer 70 may be constructed of any woven or nonwoven material that is readily penetrated by bodily exudates. The secondary absorbent layer 70 may help absorb, slow, and diffuse waves or jets of liquid that may be rapidly introduced into the absorbent article 10. Various nonwoven fabrics and webs may be used to construct the secondary absorbent layer 70. For example, the secondary absorbent layer 70 may comprise a nonwoven fabric layer composed of a meltblown or spunbond web of polyolefin or polyester filaments. Such nonwoven fabric layers may include conjugate, biconstituent, or homopolymer staple fibers or other lengths and blends of such fibers with other types of fibers. The secondary absorbent layer 70 may also be a bonded carded web or an air-laid web composed of natural and/or synthetic fibers. The bonded carded web may, for example, be a powder bonded carded web, an infrared bonded carded web, or a bonded carded web bonded by air-flow processing. The bonded carded webs may optionally include a blend or composition of different fibers. The secondary absorbent layer 70 typically has a basis weight of less than about 100 g/m2, and in some embodiments, from about 10 g/m2 to about 40 g/m2.

[0054] The secondary absorbent layer 70 may be incorporated into the absorbent article 10 in any suitable size and shape based on the need of the particular absorbent article 10 in which the secondary absorbent layer 70 is being used. In various embodiments, the secondary absorbent layer 70 may extend throughout the absorbent article 10 in the longitudinal (X) direction and the transverse (Y) direction, such that the secondary absorbent layer 70 may have the same dimensions as the topsheet layer 30, such as, for example, illustrated in FIGS. 4, 5, and 8. In various embodiments, secondary absorbent layer 70 may have a shorter overall length in the longitudinal (X) direction and a shorter overall width in the transverse (Y) direction than topsheet layer 30. In various embodiments, the overall length of secondary absorbent layer 70 may be from about 30, 40, or 50% to about 98, 99, or 100% of the overall length of topsheet layer 30. In various embodiments, the overall width of secondary absorbent layer 70 may be from about 10, 25, or 50% to about 98, 99, or 100% of the overall width of topsheet layer 30.

[0055] In various embodiments, the secondary absorbent layer 70 may have an opacity of less than 30%. In various embodiments, the secondary absorbent layer 70 may have an opacity of less than 25%.

Backsheet layer:

[0056] The backsheet layer 40 is generally impervious to liquids and is the portion of the absorbent article 10 that faces the wearer's garments. The backsheet layer 40 may permit the passage of air or vapor out of the absorbent article 10 while blocking the passage of liquids. Any liquid impervious material may generally be used to form the backsheet layer 40. The backsheet layer 40 may be composed of a single layer or multiple layers, and these one or more layers may comprise similar or dissimilar materials. Suitable backsheet material 42 that may be used to form a backsheet layer 40 may be a microporous polymeric film, such as a polyolefin or polyethylene or polypropylene film, nonwovens, and nonwoven laminates and film/nonwoven laminates. The particular structure and composition of the backsheet material 42 forming the backsheet layer 40 may be selected from various known films and/or fabrics, the particular material being selected as appropriate to provide the desired level of liquid barrier, strength, abrasion resistance, tactile properties, aesthetics, and so forth. In various embodiments, a polyethylene film may be used which may have a thickness in the range of about 0.2 or 0.5 mm to about 3.0 or 5.0 mm. An example of a backsheet layer 40 may be a polyethylene film such as that obtained from Pliant Corp., Schaumburg, IL, USA. The backsheet layer 40 may be of a single or multiple layer construction, such as of multiple layers of film or laminates of film and nonwoven fibrous layers. Suitable backsheet layers 40 may be constructed from materials such as those described in U.S. Pat. Nos. 4,578,069 to Whitehead, et al., 4,376,799 to Tusim, et al., 5,695,849 to Shawver, et al., 6,075,179 to McCormack, et al., and 6,376,095 to Cheung, et al., each of which is hereby incorporated by reference thereto in its entirety.

[0057] In various embodiments, the backsheet material 42 forming the backsheet layer 40 may have an opacity of less than 30%. In various embodiments, the backsheet material 42 forming the backsheet layer 40 may have an opacity of less than 25%. As described herein, the opacity of the topsheet layer material 36 forming the topsheet layer 30 in combination with the size of the apertures 60 can visually highlight the presence of the apertures 60 within the topsheet layer 30. Furthermore, the apertures 60 within the topsheet layer 40 in combination with the lower opacity of the backsheet layer 40 and, in various embodiments, the lower opacity of the secondary absorbent layer 70, allow the wearer of the absorbent article 10 to see through the apertures 60 and through the lower opacity backsheet layer 40 (compared to the opacity of the topsheet layer 30) and, in various embodiments, through the lower opacity secondary absorbent layer 70 (compared to the opacity of the topsheet layer 30) to see his or her undergarment within which the absorbent article 10 has been placed.

[0058] An absorbent article 10 therefore may be designed to provide discretion, since openings 60 within topsheet layer 30 may allow the wearer's undergarments to be visible through the openings 60, thereby allowing the absorbent article 10 to blend in with the wearer's undergarments, and the absorbent article 10 may be designed to indicate to the wearer that the absorbent article 10 may be breathable, since the superior opacity topsheet layer 30 may define the presence of the openings 60 that allow for breathability.

[0059] For the sake of brevity and conciseness, any ranges of values set forth in this disclosure contemplate all values within the interval and should be construed as supporting claims that recite any subintervals having endpoints that are integer values within the specified interval in question. By way of hypothetical example, a disclosure of a range of 1 to 5 should be considered to support claims for any of the following ranges: 1 to 5; 1 to 4; 1 to 3; 1 to 2; 2 to 5; 2 to 4; 2 to 3; 3 to 5; 3 to 4; and 4 to 5.

[0060] The dimensions and values disclosed herein are not to be construed as being strictly limited to the exact numerical values quoted. Rather, unless otherwise specified, each dimension is intended to mean the quoted value and a functionally equivalent range around that value. For example, a dimension disclosed as "40 mm" should be interpreted as "about 40 mm."

[0061] 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 prior art with respect to the present invention. To the extent that any meaning or definition of a term in this written document conflicts with any meaning or definition of a term in a document incorporated by reference, the meaning or definition given to the term in this written document shall control.

[0062] 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 may be made without departing from the spirit and scope of the invention. It is therefore intended to encompass in the appended claims all such changes and modifications that are within the scope of this invention.

[0063] In introducing the elements of the present disclosure or the preferred embodiment(s) thereof, the articles “a,” “the,” and “said” are intended to indicate that there is one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the elements listed. Many modifications and variations of the present disclosure may be made without departing from the spirit and scope thereof. Therefore, the exemplary embodiments described above should not be used to limit the scope of the invention.

Claims (12)

1. An absorbent article (10) comprising: a. a perimeter defined by a first transverse direction end edge (12) and a second transverse direction end edge (14) opposite the first transverse direction end edge (12), and an opposing pair of longitudinal direction side edges extending between and connecting the first transverse direction end edge (12) and the second transverse direction end edge (14); b. a topsheet layer (30) including: i. a topsheet material (36) having an opacity of at least 40%, a body-facing surface (32), and an absorbent core-facing surface (34); ii. an area defined by the perimeter of the absorbent article (10); iii. a plurality of apertures (60) extending from the body-facing surface (32) of the topsheet material (36) to the absorbent core-facing surface (34) of the topsheet material (36), wherein each aperture (60) provides an open space within the area of the topsheet layer (30), wherein each aperture (60) of the plurality of apertures (60) has a size dimension greater than 0.3 mm2; c. a backsheet layer (40) including a backsheet material (42) having an opacity of less than 30%; ed. an absorbent core (50) between the backsheet layer (40) and the topsheet layer (30), the absorbent core (50) having an opacity that is greater than the opacity of the topsheet material (36), and having a size dimension between 15% and 60% of a size dimension of the absorbent article (10). 2. The absorbent article of claim 1, wherein the opacity of the material of the top sheet layer (36) is at least 45%. 3. The absorbent article of claim 1, wherein the opacity of the material of the backsheet layer (40) is less than 25%. 4. Absorbent article according to claim 1, characterized in that the area of the upper sheet layer (30) contains from 15% to 40% open space. 5. The absorbent article of claim 1, wherein each opening (60) of the plurality of openings (60) has a dimension greater than 0.7 mm2. 6. Absorbent article according to claim 1, characterized in that it further comprises a secondary absorbent layer (70). 7. The absorbent article of claim 6, wherein the secondary absorbent layer (70) is positioned between the absorbent core (50) and the backsheet layer (40). 8. Absorbent article according to claim 6, characterized in that the secondary absorbent layer (70) has an opacity of less than 30%. 9. The absorbent article of claim 8, wherein the secondary absorbent layer (70) has an opacity of less than 25%. 10. The absorbent article of any one of claims 7, 8 or 9, wherein the secondary absorbent layer (70) comprises a nonwoven fabric layer composed of one of a meltblown or spunbond polyolefin web or polyester filaments. 11. Absorbent article according to any one of claims 7 to 10 characterized in that the secondary absorbent layer (70) has a total length of 30% to 100%, and optionally 50% to 100% of the total length of the topsheet layer (30). 12. The absorbent article of any one of claims 7, wherein the secondary absorbent layer (70) has a total width of 10% to 100%, and optionally 50% to 100%, of the total width of the topsheet layer (30).