CN106687088A - Absorbent article comprising a topsheet/acquisition layer laminate - Google Patents

Abstract

An absorbent article for personal hygiene comprises a longitudinal axis, a transversal axis perpendicular to the longitudinal axis, a liquid permeable topsheet, an acquisition layer, a liquid impermeable backsheet and an absorbent core. The absorbent core is located between the topsheet and the backsheet. The absorbent core comprises an absorbent material. The absorbent material comprises at least 80% of superabsorbent polymers, up to substantially 100% of superabsorbent polymers, by total weight of the absorbent material. The absorbent article comprises a topsheet/acquisition layer laminate comprising the liquid permeable topsheet and the acquisition layer in a face to face relationship. The topsheet/acquisition layer laminate comprises three-dimensional protrusions extending from a plane of the topsheet/acquisition layer laminate. The topsheet and acquisition layer are nested together such that a majority of the three-dimensional protrusions formed in the topsheet coincide with and fit together with a majority of the three-dimensional protrusions formed in the acquisition layer.

Description

Absorbent article comprising a topsheet/acquisition layer laminate

technical field

The present invention provides an absorbent article comprising a topsheet/acquisition layer laminate with an "airfelt-free" absorbent core. Additionally, the present invention provides an absorbent article comprising a topsheet/acquisition layer laminate and an absorbent core comprising one or more optionally regions substantially free of absorbent material.

Background technique

Absorbent articles generally comprise a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. Absorbent articles for personal hygiene such as disposable diapers for infants, training pants for toddlers or incontinence underwear for adults are designed to absorb and contain body exudates, particularly large quantities of urine. These absorbent articles comprise multiple layers providing different functions, such as a topsheet, a backsheet and an absorbent core in between, among other layers.

The function of the absorbent core is to absorb and hold exudates over extended periods of time, such as overnight use of a diaper, minimizing rewet to keep the wearer dry and avoid soiling clothing or linens. Most currently marketed absorbent articles comprise as absorbent material a blend of comminuted wood pulp with superabsorbent polymer (SAP) in particulate form, also known as absorbent gelling material (AGM), see for example US 5,151,092 (Buell). Absorbent articles having a core consisting essentially of SAP as absorbent material (so-called "airfelt-free" absorbent cores) have also been proposed, but to a lesser extent than conventional hybrid cores (see e.g. WO2008/155699 ( Hundorf), WO95/11652 (Tanzer), WO2012/052172 (Van Malderen)).

"Airfelt-free" absorbent cores provide less void area than absorbent cores comprising a blend of comminuted wood pulp and superabsorbent polymer (SAP) in particulate form. However, void volume can be used to help retain fluids and provide storage space for acquisition and absorption of fluid bodily exudates.

There is therefore a need to develop absorbent articles that provide void volume to acquire and absorb liquid body exudates.

There is also a need to develop absorbent articles comprising "airfelt-free" absorbent cores which are indicative of good absorbent properties.

Contents of the invention

The present invention provides an absorbent article for personal hygiene comprising a longitudinal axis, a transverse axis perpendicular to the longitudinal axis, a liquid pervious topsheet, an acquisition layer, a liquid impermeable backsheet and an absorbent core . The topsheet and acquisition layer comprise fibers. The absorbent core is positioned between the topsheet and the backsheet. The absorbent core contains absorbent material. The absorbent material comprises at least 80% superabsorbent polymer, up to substantially 100% superabsorbent polymer, based on the total weight of the absorbent material. The width of the acquisition layer in a direction parallel to the transverse axis is less than the width of the topsheet in a direction parallel to the transverse axis. The absorbent article comprises a topsheet/acquisition layer laminate comprising a liquid-permeable topsheet and an acquisition layer in face-to-face relationship. The topsheet/acquisition layer laminate includes three-dimensional protrusions extending from the plane of the topsheet/acquisition layer laminate. The topsheet and acquisition layer are nested together such that most of the three-dimensional protrusions formed in the topsheet coincide and fit together with most of the three-dimensional protrusions formed in the acquisition layer.

The width of the acquisition layer of the topsheet/acquisition layer laminate may extend by no more than 40% of the width of the distribution layer in a direction parallel to the transverse axis and/or no more than 20% of the width of the absorbent core.

The absorbent article may include a collar cuff.

Said majority of the three-dimensional protrusions of the topsheet/acquisition layer laminate may be present at least or only in the region where the topsheet in the topsheet/acquisition layer laminate overlaps the acquisition layer.

Said majority of the three-dimensional protrusions of the topsheet/acquisition layer laminate may be present in regions extending parallel to the transverse axis of the absorbent article. The majority of the three-dimensional protrusions of the topsheet/acquisition layer laminate may be present in a region parallel to the longitudinal axis of the absorbent article, but not extending beyond the region where the collar cuffs are attached to the absorbent article. In said case, said majority of the three-dimensional protrusions formed in the topsheet of the topsheet/acquisition layer laminate are formed by fibers of the topsheet.

The absorbent article can be hypothetically divided into a front region, a rear region, and a crotch region between the front region and the rear region, wherein the front region, the rear region and the crotch region are each 1% of the length of the absorbent article in a direction parallel to the longitudinal axis. /3, wherein the acquisition layer in the topsheet/acquisition layer laminate is positioned in the front region and at least partially in the crotch region.

Alternatively, the absorbent article can be fictitiously divided into a front region, a rear region, and a crotch region between the front region and the rear region, wherein along a direction parallel to the longitudinal axis, each of the front region, the rear region, and the crotch region is an absorbent 1/3 of the length of the article with the acquisition layer in the topsheet/acquisition layer laminate positioned in the back region and at least partially in the crotch region.

The three-dimensional protrusions of the topsheet/acquisition layer laminate may protrude towards the backsheet or towards the body of the wearer when the absorbent article is in use.

The majority of three-dimensional protrusions may be more than 50% or more than 60% or more than 70% or more than 80% or more than 90% or more than 95% or more than 98% of the three-dimensional protrusions in the topsheet/acquisition layer laminate.

Description of drawings

While the specification concludes by claims which particularly point out and distinctly claim the invention, it is believed that the invention will be better understood from the following description when read in conjunction with the accompanying drawings, in which:

Figure 1 is an absorbent article according to the present invention in the form of a diaper comprising an exemplary topsheet/acquisition layer laminate, wherein the acquisition layer has a length that is less than the length of the topsheet, with some layers partially removed;

Figure 2 is a transverse section of the diaper of Figure 1;

Figure 3 is a transverse section of the diaper of Figure 1;

Figure 4 is an absorbent article according to the present invention in the form of a diaper comprising an exemplary topsheet/acquisition layer laminate wherein the three-dimensional protrusions of the topsheet/acquisition layer laminate are formed only on the topsheet/acquisition layer laminate Where the topsheet overlaps the acquisition layer, some of the layers are partially removed;

Figure 5 is an absorbent article according to the present invention in the form of a diaper comprising an exemplary topsheet/acquisition layer laminate with another type of absorbent core with some layers partially removed;

Figure 6 is a transverse section of the diaper of Figure 5;

Figure 7 is a transverse cross-section of the absorbent article of Figure 5, taken at the same point as Figure 6, wherein channels have been formed as a result of the absorbent article being loaded with liquid bodily exudates;

Figure 8 is an absorbent article according to the present invention in the form of a diaper comprising an exemplary topsheet/acquisition layer laminate with the same type of absorbent as the absorbent core in Figure 5. Core, but with one or more regions of the topsheet/acquisition layer laminate that are substantially free of three-dimensional protrusions, wherein some layers are partially removed;

Figure 9 is a transverse section of the diaper of Figure 8;

Figure 10 is a transverse cross-section of the absorbent article of Figure 8, taken at the same point as Figure 9, wherein channels have been formed due to loading of the absorbent article with liquid bodily exudates;

Figure 11 is an absorbent article according to the present invention in the form of a diaper comprising an exemplary topsheet/acquisition layer laminate with a carrier layer with some layers partially removed;

Figure 12A is a transverse cross-section of the diaper of Figure 11;

Figure 12B is another transverse section of the diaper of Figure 11;

Figure 13 is an absorbent article according to the present invention in the form of a diaper comprising an exemplary topsheet/acquisition layer laminate with a carrier layer with some layers partially removed;

Figure 14 is a transverse section of the diaper of Figure 13;

Figure 15 is an absorbent article according to the present invention in the form of a diaper comprising an exemplary topsheet/acquisition layer laminate with an acquisition layer positioned in the front region of the absorbent article with some layers partially removed remove;

Figure 16 is an absorbent article according to the present invention in the form of a diaper comprising an exemplary topsheet/acquisition layer laminate with an acquisition layer positioned in the rear region of the absorbent article with some layers partially removed remove;

Figure 17 is a perspective view of an apparatus comprising first and second intermeshing rolls for forming the topsheet/acquisition layer laminate of the present invention;

Figure 18A is a cross-sectional view of a portion of the apparatus shown in Figure 17;

Figure 18B is a perspective view of a portion of a second intermeshing roller of the apparatus shown in Figure 17;

Fig. 19 A is the schematic diagram of the three-dimensional protrusion of the topsheet/acquisition layer laminate obtained with the apparatus shown in Fig. 17;

Figure 19B is a perspective view of a three-dimensional protrusion of the topsheet/acquisition layer laminate shown in Figure 19A;

Figure 19C is another perspective view of the three-dimensional protrusions of the topsheet/acquisition layer laminate shown in Figure 19A;

Figure 19D is a schematic diagram of a three-dimensional projection of a topsheet/acquisition layer laminate obtained with the apparatus shown in Figure 17;

Figure 19E is a schematic diagram of a three-dimensional projection of a topsheet/acquisition layer laminate obtained with the apparatus shown in Figure 17;

Figure 19F is a schematic diagram of a three-dimensional projection of a topsheet/acquisition layer laminate obtained with the apparatus shown in Figure 17;

20A is a schematic diagram of a three-dimensional projection of a topsheet/acquisition layer laminate obtained with the apparatus shown in FIG. 17;

Figure 20B is a schematic diagram of a three-dimensional projection of a topsheet/acquisition layer laminate obtained with the apparatus shown in Figure 17;

Figure 20C is a schematic diagram of a three-dimensional projection of a topsheet/acquisition layer laminate obtained with the apparatus shown in Figure 17;

20D is a schematic illustration of a three-dimensional protrusion of a topsheet/acquisition layer laminate obtained with the apparatus shown in FIG. 17. FIG.

detailed description

Definition of terms

As used herein, the term "absorbent article" refers to disposable products, such as diapers, pants and feminine hygiene napkins, which are placed next to or adjacent to the wearer's body to absorb and contain various liquid bodily exudates from the body. These absorbent articles generally comprise a topsheet, a backsheet, an absorbent core and optionally an acquisition and/or distribution layer and other components, wherein the absorbent core is usually positioned between the backsheet and the acquisition system or topsheet. Absorbent articles of the present invention may be diapers or pants.

As used herein, the term "absorbent core" refers to the component which is placed or intended to be placed within an absorbent article and which comprises absorbent material enclosed in a core wrap. The term "absorbent core" does not encompass acquisition or distribution layers or any other component of an absorbent article that is not an integral part of or placed within a core wrap. The absorbent core is generally the component of an absorbent article comprising all or at least a majority of superabsorbent polymer and having the highest absorbent capacity of all components of said absorbent article.

As used herein, the term "substantially free of absorbent material" means that the basis weight of absorbent material is at least less than 10%, specifically less than 5% or 2%, of the average basis weight of absorbent material in the remainder of the absorbent core.

As used herein, the term "superabsorbent polymer" (abbreviated herein as "SAP") refers to absorbent materials which are cross-linked polymeric 05E), said polymeric materials are capable of absorbing at least 10 times their weight in aqueous 0.9% saline solution. The SAP of the invention may specifically have a CRC value of more than 20 g/g, or more than 25 g/g, or 20 to 50 g/g, or 20 to 40 g/g, or 25 to 35 g/g. SAPs useful in the present invention include a variety of water-insoluble but water-swellable polymers capable of absorbing large volumes of liquid bodily exudates.

As used herein, the term "diaper" refers to an absorbent article intended to be worn by the wearer about the lower torso to absorb and contain liquid bodily exudates from the body. Diapers can be worn by young children (such as infants or toddlers) or adults. They can have fastening elements.

As used herein, the term "pant" refers to an absorbent article having fixed edges, a waist opening, and leg openings designed for infant or adult wearers. The pant is applied to the wearer by inserting the wearer's legs into the leg openings and pulling the pant-type absorbent article into position about the wearer's lower torso. Pants can be preformed using any suitable method, including but not limited to utilizing refastenable and/or non-refastenable bonds (e.g., seaming, welding, adhesives, cohesive bonding, fasteners, etc. ) to join parts of the article together. Pants can be preformed anywhere along the perimeter of the article (eg, side fastened, front waist fastened).

As used herein, the term "extensible" refers to a material that, when subjected to the following test, is capable of extending along the longitudinal axis and/or the transverse direction of the absorbent article when a force is applied, at or before the breaking force is reached: The axis undergoes an apparent elongation equal to or greater than at least 100% of its original length:

The longitudinal axis tensile properties and/or transverse axis tensile properties are measured using method WSP 110.4(05) Option at a specimen width of 50 mm, a gauge length of 60 mm, and a rate of extension of 60 mm/min.

According to the "Test Method" described above, it is expected that the material will be able to experience equal to or greater than at least 100% or 110% or 120% or 130% along the longitudinal axis and/or transverse axis of the absorbent article at or before reaching the breaking force. % up to 200% apparent elongation.

A material is "non-extensible," as used herein, if it is capable of undergoing an apparent elongation of less than 100% of its original length (if subjected to the above test).

As used herein, the term "topsheet/acquisition layer laminate" refers to the intimate combination of a topsheet and an acquisition layer disposed in face-to-face relationship. The topsheet has a first surface and a second surface. The first surface of the topsheet faces the wearer's body when the absorbent article is in use. The acquisition layer faces the negative or optional distribution layer. During combining the topsheet web and the acquisition layer with each other to form the topsheet/acquisition layer laminate web, the topsheet web and the acquisition layer may have undergone simultaneous and joint mechanical deformation, the topsheet/acquisition layer The Laminate Web provides each topsheet/acquisition layer laminate in each absorbent article. The topsheet/acquisition layer laminate includes deformations that form three-dimensional protrusions. A topsheet/acquisition layer laminate is formed by nesting the topsheet and acquisition layer together such that most of the three-dimensional protrusions formed in the topsheet coincide with and fit over most of the three-dimensional protrusions formed in the acquisition layer. Together, as shown in Figures 19A, 19B, 19C and 20A.

In topsheet/acquisition layer laminates, the topsheet and acquisition layer may be in intimate contact with each other.

In the three-dimensional protrusion region of the topsheet/acquisition layer laminate, there is no interpenetration of one of the topsheet or acquisition layer into and through the corresponding other topsheet or acquisition layer. The topsheet and acquisition layer are thus extensible such that the topsheet and/or acquisition layer cannot rupture and interpenetrate into and through a ruptured topsheet or acquisition layer.

In the region of the three-dimensional protrusions, the topsheet and/or the acquisition layer may comprise one or more interruptions. The formation of the one or more interruptions may be attributed to the properties of the topsheet and the acquisition layer, i.e. the apparent elongation of the fibers, the mobility of the fibers, the areas in which the three-dimensional protrusions of the topsheet/acquisition layer laminate are formed deformability and stretchability. In other words, the topsheet may be less extensible than the acquisition layer or vice versa; however, a non-ruptured topsheet or acquisition layer does not interpenetrate a corresponding ruptured topsheet or acquisition layer.

Therefore, the topsheet/acquisition layer laminate can be formed by interrupting one of the topsheet or the acquisition layer in the three-dimensional protrusion region of the topsheet/acquisition layer laminate so that the corresponding other non-interrupted topsheet or acquisition layer The three-dimensional protrusions of the layer are at least partially bonded to the three-dimensional protrusions of the interrupted topsheet or acquisition layer, as shown in Figures 19D, 19E, 20B and 20C.

Alternatively or in addition to the above, the topsheet/acquisition layer laminate can also be formed by interrupting the topsheet and acquisition layer in the three-dimensional raised region of the topsheet/acquisition layer laminate, and topsheet/acquisition layer laminate The three-dimensional protrusions of the sheet and the three-dimensional protrusions of the acquisition layer are overlapped and bonded together. The discontinuity in the topsheet in the three-dimensional protrusion region of the topsheet/acquisition layer laminate may not coincide with the discontinuity in the acquisition layer in the three-dimensional protrusion region of the topsheet/acquisition layer laminate, as shown in Figures 19F and 20D Show.

As used herein, the term "interruption" refers to a hole formed in the topsheet and/or acquisition layer during formation of the topsheet/acquisition layer laminate, and does not include gaps between fibers that are typically present in nonwoven materials. Pores and gaps.

As used herein, the term "mechanically deformed and combined" means that the topsheet web and the acquisition layer are placed in face-to-face relationship and simultaneously can be mechanically deformed between a first roll and a second roll, and are simultaneously intimately combined . Mechanical deformation of the topsheet web and acquisition layer depends on the process, equipment required, but also on the properties of the topsheet and acquisition layer, i.e. apparent elongation of fibers, fiber mobility, formation of the topsheet in /Ability to deform and stretch in the three-dimensional protrusion region of the acquisition layer laminate, ability to undergo plastic deformation which is set after use of first and second rollers or after partial rebound due to elastic recovery .

The mechanical deforming may comprise intermeshing the topsheet together with the acquisition layer between a first intermeshing roll and a second intermeshing roll. The first intermeshing roller includes a plurality of ridges and corresponding grooves. The second intermeshing roll comprises a plurality of rows of circumferentially spaced teeth and corresponding grooves, such that a plurality of deformations comprising three-dimensional protrusions is obtained. A tunnel-shaped ring may be a type of three-dimensional protrusion.

For each 3D protrusion:

- the topsheet is nested into the acquisition layer or vice versa such that said majority of three-dimensional protrusions of the topsheet and said majority of three-dimensional protrusions of the acquisition layer coincide and fit together, as in Figures 19A, 19B, 19C and 20A. In the three-dimensional protrusion region of the topsheet/acquisition layer laminate, there is no interpenetration of one of the topsheet or acquisition layer into or through the corresponding other topsheet or acquisition layer.

-In addition to the above, one of the topsheet or acquisition layer can be interrupted in the three-dimensional protrusion area of the topsheet/acquisition layer laminate, so that it is made from a corresponding other non-interrupted topsheet or acquisition layer The three-dimensional protrusions of the three-dimensional protrusions of the interrupted topsheet or the three-dimensional protrusions of the interrupted acquisition layer are at least partially bonded together, as shown in Figures 19D, 19E, 20B and 20C.

- Alternatively or in addition to the above, the topsheet and acquisition layer can be interrupted in the area of the three-dimensional protrusions of the topsheet/acquisition layer laminate, and the three-dimensional protrusions of the topsheet are separated from the three-dimensional protrusions of the acquisition layer Fold and snap together. The discontinuity in the topsheet in the three-dimensional protrusion region of the topsheet/acquisition layer laminate may not coincide with the discontinuity in the acquisition layer in the three-dimensional protrusion region of the topsheet/acquisition layer laminate, as shown in Figures 19F and 20D Show.

As used herein, the term "majority of three-dimensional protrusions" refers to more than 50% or more than 50% or more of the three-dimensional protrusions in the topsheet/acquisition layer laminate web or the three-dimensional protrusions in the topsheet/acquisition layer laminate of an absorbent article. 60% or more than 70% or more than 80% or more than 90% or more than 95% or more than 98%, each of which includes a base forming an opening and having a protrusion base width, an opposing distal portion, and a base interposed by a three-dimensional protrusion and one or more side walls between the distal portion. The base, distal portion, and one or more sidewalls are formed from fibers such that the three-dimensional protrusion has openings only at the base (as exemplarily shown in FIG. 19A ).

As used herein, the term "tunnel-shaped loops" means that the three-dimensional protrusions of the topsheet/acquisition layer laminate are defined by a plurality of loops extending from the topsheet to the acquisition layer or from the acquisition layer to the topsheet. The plurality of loops comprises one or more fibers made from a topsheet/acquisition layer laminate. The fibers of the plurality of loops are substantially aligned with each other such that the plurality of loops form a tunnel-shaped loop. A tunnel-shaped ring may be defined as a semi-cylindania, ie a cylinder cut in half along its length, comprising an opening at each end of said tunnel-shaped ring and a base opening.

As used herein, the term "cellulosic fibers" refers to natural fibers, typically wood pulp fibers. Applicable wood pulps include chemical pulps, such as kraft, sulfite, and kraft pulps, and mechanical pulps, including, for example, groundwood, thermodynamic pulp, and chemically modified thermodynamic pulp. Wood pulp from deciduous trees (hereinafter also referred to as "hardwood") and coniferous trees (hereinafter also referred to as "softwood") may also be utilized. Hardwood fibers and softwood fibers may be blended, or alternatively, deposited in layers to provide a layered web.

As used herein, the term "dry-laid fibers" refers to fibers provided in a gaseous fluid medium (air).

As used herein, the term "wet-laid fibers" includes cellulosic fibers that are suspended in an aqueous medium, such as water, prior to being converted into a web and dried according to the wet-laid papermaking process.

As used herein, the term "web" refers to a material capable of being wound into a roll. The web can be a nonwoven material.

As used herein, the term "nonwoven web" refers to a manufactured material, web, sheet or batt of oriented or randomly oriented fibers bonded by friction and/or gluing and/or adhesion, not Products including paper and yarns or filaments combined by weaving, weaving, tufting, stitchbonding, whether or not otherwise sewn. Fibers may be of natural or man-made origin. The fibers may be staple or continuous filaments or formed in situ. The porous fibrous structure of the nonwoven can be configured to be liquid permeable or impermeable as desired.

As used herein, the term "area substantially free of three-dimensional protrusions" means less than 10%, specifically less than 5%, or less than 2%, or no three-dimensional protrusions at all, of the entire surface of the area comprising three-dimensional protrusions area.

The region substantially free of three-dimensional protrusions may have a length L' projected onto the longitudinal axis of the absorbent article which is at least 10% of the length L of the article. The region substantially free of three-dimensional protrusions may have a width of at least 2 mm, or at least 3 mm or at least 4 mm, at least 8 mm, at least 10 mm, up to, for example, 20 mm, or 16 mm or 12 mm along at least part of its length or along the entire length L' W'. The width of the region free of substantially three-dimensional protrusions may be constant over substantially the entire length of the region free of three-dimensional protrusions or may vary along its length.

As used herein, the term "joined to" includes configurations in which an element is directly secured to another element by directly attaching the element to another element, as well as by attaching the element to one or more intermediate elements, which A configuration in which an element is in turn attached to another element, while indirectly securing an element to another element. The term "bonded to" encompasses configurations that secure an element to another element at a selected location, as well as configurations that completely secure an element to another element across the entire surface of one of the elements. The term "bonded to" includes any known means by which an element may be secured, including but not limited to mechanical entanglement.

As used herein, the term "joined adjacent to a lateral edge" means when the first lateral edge and/or the second lateral edge of the first layer is joined adjacent to the first lateral edge and/or the second lateral edge of the second layer. , the first lateral edge and/or the second lateral edge of the first layer is disposed in a region spaced inwardly from the first lateral edge and/or the second lateral edge of the second layer. The region has a width that is 1 to 30% of the width of the second layer.

"Comprising", "comprising" or "containing" are open-ended terms, each specifying the presence of a component stated thereafter, for example, but not excluding other features such as elements, steps, known in the art or disclosed herein. , The presence of components. These terms based on the verb "to comprise" should be read to cover the narrower term "consisting essentially of", which excludes any unmentioned element that significantly affects the manner in which the described features perform their function, step or ingredient; and encompasses the term "consisting of" which excludes any element, step or ingredient not specified. Any preferred or exemplary embodiments described below do not limit the scope of the claims unless expressly stated to do so. The words "generally," "often," "advantageously," etc. also define features and are not intended to limit the scope of the claims unless expressly stated to do so.

Absorbent cores without airfelt provide less void area than absorbent cores comprising a blend of comminuted wood pulp and superabsorbent polymer (SAP) in particulate form. However, void volume can be used to help retain fluids and provide storage space for acquisition and absorption of fluid bodily exudates.

Known three-dimensional topsheets can be used to provide additional void volume to absorbent articles. Known three-dimensional topsheets are often obtained with increased basis weight and raisedness of the topsheet. In addition, such relatively high basis weights and fuzziness (ie relatively high void volume) for three-dimensional topsheets may lead to increased wettability of three-dimensional topsheets because more liquid remains in the topsheet. Especially three-dimensional topsheets include small pores which may be more difficult to dewater by the secondary topsheet or acquisition layer.

One solution could be to eliminate any secondary topsheet or acquisition layer in order to place the three-dimensional topsheet in direct contact with the absorbent core. In addition, this may lead to an increase in acquisition time and thus to an increased risk of leakage. This risk can be reduced by incorporating a relatively high amount of superabsorbent material in the "airfelt-free" absorbent core. However, the solution of incorporating a relatively high amount of absorbent material in an "airfelt-free" absorbent core adversely affects the cost of the absorbent article and also leads to an increase in the thickness of the overall absorbent article.

It has been found that having the topsheet and the acquisition layer in a face-to-face relationship and making the topsheet/acquisition layer laminate include three-dimensional protrusions extending from the plane of the topsheet/acquisition layer laminate can help provide additional void volume without affecting the facing orientation of the absorbent article. Dryness at the skin layer. The topsheet and acquisition layer are nested together such that most of the three-dimensional protrusions formed in the topsheet coincide and fit together with most of the three-dimensional protrusions formed in the acquisition layer.

General Description of Absorbent Article 20

An exemplary absorbent article 20 in which the absorbent core 28 of the present invention may be used is a taped diaper 20 with various absorbent core configurations as shown in FIGS. 1 , 4 and 5 . FIGS. 1 , 4 and 5 are top plan views of an exemplary diaper 20 in a flattened state with portions of the structure cut away to more clearly show the configuration of the diaper 20 . The diaper 20 is shown for illustrative purposes only, as the invention may be used to prepare a variety of diapers or other absorbent articles.

The absorbent article 20 includes a topsheet/acquisition layer laminate 245 formed from a liquid permeable topsheet 24 and an acquisition layer 52 . In other words, the absorbent article 20 comprises a liquid permeable topsheet 24 and an acquisition layer 52 characterized in that the topsheet 24 and the acquisition layer 52 are joined to form a topsheet/acquisition layer laminate 245 . The absorbent article 20 includes a liquid impermeable backsheet 25 and an absorbent core 28 interposed between the topsheet 24 and the backsheet 25 . The absorbent article 20 includes a front edge 10 , a rear edge 12 , and two longitudinal side edges 13 . The front edge 10 is the edge of the absorbent article 20 which, when worn, is intended to lie towards the front of the user, and the rear edge 12 is the opposite edge. When the absorbent article 20 is viewed from the side facing the wearer in the flat configuration, the absorbent article 20 can be imaginarily divided by a longitudinal axis 80 which extends from the front edge 10 to the rear edge 12 of the absorbent article 20 and which will absorb the The article 20 is divided with respect to this axis into two substantially symmetrical halves, as exemplarily shown in FIGS. 1 , 4 and 5 .

The absorbent article 20 can include a distribution layer 54, which can include a dry-laid fibrous structure or a wet-laid fibrous structure. The topsheet/acquisition layer laminate 245 faces the wearer's body when the absorbent article 20 is in use.

A wet-laid fibrous structure comprising wet-laid fibers may have a "wet burst strength" of 50 to 500 g, and combinations thereof, according to the "Wet Burst Strength Test Method".

Distribution layer 54 may comprise a dry-laid fibrous structure. The dry-laid fibrous structure may include dry-laid fibers 540 . The dry-laid fibrous structure may comprise a mixture of superabsorbent polymer and dry-laid fibers 450 . Dry-laid fibers may include intrafiber crosslinked cellulosic fibers.

The distribution layer 54 may have an average basis weight of 30 to 400 gsm, specifically 100 to 300 gsm or 50 to 250 gsm.

As detailed in the process detailed below, the topsheet 24 and acquisition layer 52 can be simultaneously mechanically deformed and brought together to form a topsheet/acquisition layer laminate 245 . The mechanical deformations provide a three-dimensional structure to the topsheet/acquisition layer laminate 245 . The topsheet 24 and acquisition layer 52 are nested together such that most of the three-dimensional protrusions formed in the topsheet 24 coincide with and fit together most of the three-dimensional protrusions formed in the acquisition layer 52 .

The topsheet 24 and the acquisition layer 52 may be in intimate contact with each other.

The absorbent article 20 may include an elasticized gusset cuff 32 and an upstanding barrier leg cuff 34 disposed between the topsheet 24 and the backsheet 25 . Figures 1, 4 and 5 also show other typical diaper components, such as a fastening system comprising fastening tabs 42 attached towards the rear edge 12 of the absorbent article 20 and towards the rear edge 12 of the absorbent article 20. Front edge 10 cooperates with landing zone 44 . The absorbent article 20 may also include other typical features not shown in the figures, such as a rear elastic waist structure, a front elastic waist structure, one or more lateral barrier cuffs, lotion application, and the like.

As shown in Figure 7, the barrier leg cuffs 34 may be bounded by a proximal edge 64 joined to the remainder of the absorbent article 20 (typically the topsheet 24 and/or the backsheet 25) and free end borders, which are intended to conform to the wearer's The skin touches and forms a seal. Barrier leg cuff 34 may be joined at proximal edge 64 by bond 65, which may be made, for example, by adhesive bonding, fusion bonding, or a combination of known bonding methods. Each barrier leg cuff 34 may include one, two or more elastic threads 35 to provide a better seal. The gasket collar 32 may be positioned laterally outboard relative to the barrier leg collar 34 . The gasket cuff 32 can provide a better seal around the wearer's thigh. Typically each gasketed leg cuff 32 will include one or more elastic threads or elements 33, for example between the topsheet 24 and the backsheet 25 in the leg opening area.

The absorbent article 20 can also be imaginarily divided by the transverse axis 90 into front and rear regions having equal lengths measured along the longitudinal axis when the absorbent article 20 is in a flat state. The transverse axis 90 of the absorbent article is perpendicular to the longitudinal axis 80 and is positioned half the length of the absorbent article 20 . The length of the absorbent article 20 may be measured along the longitudinal axis 80 from the front edge 10 to the rear edge 12 of the absorbent article 20 . The topsheet 24 , acquisition layer 52 , distribution layer 54 and absorbent core 28 each have a width that can be measured from their respective transverse edges and parallel to the transverse axis 90 .

The absorbent article 20 is imaginary divided into a front region 36, a rear region 38 and a crotch region 37 located between the front region and the rear region of the absorbent article 20. The front, back and crotch regions are each 1/3 of the length of the absorbent article 20 . The absorbent article may also include front ears 46 and back ears 40, as is known in the art.

The absorbent core 28 of the present invention may comprise an absorbent material 60 that is a blend of cellulosic fibers (so-called "airfelt") and superabsorbent polymers, the blend being encapsulated in one or more Particulate forms in various substrates, see eg US 5,151,092 (Buell). Alternatively, the absorbent core 28 may be free of airfelt, as described in more detail below.

In general, an absorbent core 28 useful in the present invention (see below) may be defined by a perimeter of a layer formed of absorbent material 60 within a core wrap 160 as viewed from the top side of the absorbent core 28 . The absorbent core 28 can take a variety of shapes, in particular exhibiting a so-called "dogbone" or "hourglass" shape which exhibits a taper along its width towards the central or "crotch" region of the core. As such, the absorbent core 28 may have a relatively narrow width in the region of the absorbent core 28 intended to be placed in the crotch region of the absorbent article. This can provide, for example, better wearing comfort. Accordingly, the absorbent core 28 may have a width (as measured in the transverse direction) at its narrowest point of less than about 100 mm, 90 mm, 80 mm, 70 mm, 60 mm, or even less than about 50 mm. The absorbent core 28 can also be generally rectangular, see eg FIG. 5, although other deposition regions such as "T" or "Y" or "hourglass" or "dogbone" shapes can be used (see eg FIG. 4).

Some components of the absorbent article 20 will now be discussed in greater detail.

"Airfelt Free" Absorbent Core 28

The absorbent core 28 of the present invention may include absorbent material 60 enclosed within a core wrap 160 . The absorbent material 60 may comprise 80% to 100% SAP, such as SAP particles, based on the total weight of the absorbent material 60 . The core wrap 160 is not considered absorbent material 60 for purposes of evaluating the percentage of SAP in the absorbent core 28 .

By "absorbent material" is meant a material having at least some absorbent and/or liquid-retaining properties, such as SAP, cellulosic fibers, and some hydrophilically treated synthetic fibers. Typically, the binders used to make absorbent cores do not have absorbent properties and are not considered absorbent materials. The SAP content may be substantially greater than 80%, such as at least 85%, at least 90%, at least 95% and even up to and including 100%, by weight of the absorbent material 60 contained within the core wrap 160. Such a SAP content substantially higher than 80% SAP may provide a relatively thin absorbent core compared to conventional absorbent cores typically comprising between 40-60% SAP and between 40-60% cellulose fibers 28. The absorbent material 60 of the present invention may specifically comprise less than 10% by weight, or less than 5% by weight of natural and/or synthetic fibers, or even be substantially free of natural and/or synthetic fibers. The absorbent material 60 may advantageously comprise little or no cellulose fibers, specifically the absorbent core 28 may comprise less than 15%, 10%, or 5% (airfelt) fibers by weight of the absorbent core 28. cellulose fibers, or even substantially free of cellulose fibers. Such absorbent cores 28 can be relatively thin, and thinner than conventional airfelt cores. 1 , 2 and 3 are illustrations of an absorbent article 20 comprising an absorbent core 28 "without airfelt".

"Airfelt-free" absorbent cores 28 comprising relatively high amounts of SAP have been proposed in the past with various absorbent core designs, see e.g. /0312622A1 (Hundorf), and WO2012/052172 (Van Malderen).

The absorbent core 28 of the present invention may include, for example, adhesives to help secure the SAP within the core wrap 160, and/or ensure the integrity of the core wrap 160, particularly when the core wrap 160 is made of one or more substrates. Chengshi. The core wrap 160 will generally extend over a larger area than is strictly required to contain the absorbent material 60 therein.

core wrap

Absorbent material 60 is encapsulated in one or more substrates.

The core wrap 160 includes a top side 16 facing the topsheet 24 and a bottom side 16 facing the backsheet 25 . The core wrap 160 may be made from a single substrate folded around the absorbent material 60 . The core wrap 160 may be made of two substrates (one mainly providing the top side 16 and the other mainly providing the bottom side 16') attached to each other, as exemplarily shown in FIG. 2 . Typical configurations are so-called C-wraps and/or sandwich wraps. In a C-wrap, as exemplarily shown in Figure 6, the longitudinal and/or transverse edges of one substrate are folded over the other substrate to form wings. These tabs are then bonded to the outer surface of another substrate, usually by bonding with an adhesive. The so-called C-wrap configuration may provide benefits such as improved rupture resistance under wet loading compared to sandwich seals.

The core wrap 160 may be formed from any material suitable for receiving and containing the absorbent material 60 . The core wrap 160 may specifically be formed from a nonwoven web, such as a carded nonwoven, a spunbond nonwoven ("S"), or a meltblown nonwoven ("M"), as well as laminates of any of these materials. For example, melt spun polypropylene nonwovens are suitable, particularly those having a laminated web SMS, or SMMS or SSMMS construction, and having a basis weight in the range of about 5 gsm to 15 gsm. Suitable materials are disclosed, for example, in US 7,744,576, US2011/0268932A1, US2011/0319848A1 or US2011/0250413A1. Nonwoven materials provided by synthetic fibers such as polyethylene (PE), polyethylene terephthalate (PET) and especially polypropylene (PP) may be used.

"Airfelt-free" absorbent core 28 comprising regions 26 substantially free of absorbent material

The absorbent core 28 may include an absorbent material deposition area 8 defined by the perimeter of the layer formed by the absorbent material 60 within the core wrap 160 .

The absorbent core 28 may include one or more substantially absorbent material-free regions 26 that are substantially free of absorbent material 60 and through which a portion of the top side 16 of the core wrap 160 is wrapped by the one or more cores. A material bond 27 is attached to a portion of the bottom side 16' of the core wrap 160, as shown in FIGS. 5 and 6 . Specifically, absorbent material 60 may be absent in these regions. Small amounts of contamination such as with absorbent material 60 that may occur during the manufacturing process are not considered absorbent material. The one or more substantially absorbent material-free regions 26 may advantageously be bounded by absorbent material 60 , which means that the substantially absorbent material-free regions 26 do not extend to either edge of the absorbent material deposition region 8 .

If the substantially absorbent material-free region 26 extends to either edge of the absorbent material-depositing region 8, each substantially absorbent material-free region 26 may be located at either side of each substantially absorbent material-free region 26. There are areas of absorbent material 60 on the sides.

The absorbent core 28 may include at least two regions 26 substantially free of absorbent material disposed symmetrically on either side of the longitudinal axis of the absorbent core 28, as shown in FIG. 5 .

The region 26 substantially free of absorbent material may be straight and oriented entirely longitudinally and parallel to the longitudinal axis, but may also be curved or have one or more curved portions.

Furthermore, in order to reduce the risk of leakage of liquid bodily exudates, the region 26 substantially free of absorbent material advantageously does not extend up to either edge of the absorbent material-deposited region 8 and is therefore surrounded by the absorbent material-deposited region 8 of the absorbent core 28 and is completely contained within the absorbent material deposition area. Typically, the minimum distance between the region 26 substantially free of absorbent material and the nearest edge of the absorbent material deposited region 8 is at least 5 mm.

"Airfelt-free" absorbent cores 28 comprising regions 26 essentially free of absorbent material have been proposed, see eg European patent application 12196341.7.

As the absorbent material 60 absorbs liquid and begins to swell, one or more channels 26' in the absorbent core 28 along the regions 26 that are substantially free of absorbent material may begin to form. As the absorbent core 28 absorbs more liquid, the recesses in the absorbent core 28 formed by the channels 26' will become deeper and easier to see and touch. The formation of channel 26' can also be used to indicate that the absorbent article 20 has been loaded with liquid bodily exudates. The core wrap bond 27 should remain substantially intact at least during the first stage in which the absorbent material 60 absorbs moderate volumes of liquid bodily exudates.

As shown in Figure 7, when the absorbent material swells, the core wrap bond 27 remains at least initially attached in the region 26 that is substantially free of absorbent material. The absorbent material 60 in the remainder of the absorbent core 28 swells as it absorbs liquid such that the core wrap 160 thus forms channels 26'

General Structure and Properties of Topsheet/Acquisition Layer Laminates

The present invention provides a topsheet/acquisition layer laminate 245 having a three-dimensional structure.

The absorbent article 20 includes a longitudinal axis 80, a transverse axis 90 perpendicular to the longitudinal axis 90, a liquid pervious topsheet 24 having a first surface and a second surface, and an acquisition layer 52 having a first surface and a second surface. When the absorbent article 20 is in use, the first surface of the topsheet will face the wearer's body.

The topsheet 24 and acquisition layer 52 are aligned in face-to-face relationship such that the second surface of the topsheet 24 contacts the first surface of the acquisition layer 52 . The topsheet 24 and acquisition layer 52 comprise fibers.

The absorbent article 20 includes a topsheet/acquisition layer laminate 245 comprising the topsheet 24 and the acquisition layer 52 in face-to-face relationship. The topsheet 24 and the acquisition layer 52 are nested together such that most of the three-dimensional protrusions formed in the topsheet 24 coincide and fit together with most of the three-dimensional protrusions formed in the acquisition layer 52, thereby providing a three-dimensional Topsheet/acquisition layer laminate 245 of raised portion 250.

The majority of three-dimensional protrusions 250 may be more than 50% or more than 60% or more than 70% or more than 80% or more than 90% or more than 95% or more of the three-dimensional protrusions 250 in the topsheet/acquisition layer laminate 245. 98%.

The topsheet 24 and acquisition layer 52 can be simultaneously mechanically deformed and brought together in face-to-face relationship to provide a topsheet/acquisition layer laminate 245 according to the process detailed below. This means that both the topsheet 24 and the acquisition layer 52 can be mechanically deformed and brought together simultaneously. The topsheet/acquisition layer laminate 245 has a first surface that includes the second surface of the acquisition layer 52 .

The absorbent article 20 can comprise a dry-laid fibrous structure or a wet-laid fibrous structure. The distribution layer 54 may be free of tow fibers.

Distribution layer 54 may, for example, comprise at least 50% by weight crosslinked cellulosic fibers. The crosslinked cellulosic fibers may be crimped, twisted, or crimped, or combinations thereof (including crimped, twisted, and crimped). This type of material has been used in the past in disposable diapers as part of an acquisition system, eg US 2008/0312622 A1 (Hundorf).

Exemplary chemically crosslinked cellulosic fibers suitable for distribution layer 54 are disclosed in US 5,549,791 , US 5,137,537 , WO9534329 or US2007/118087. Exemplary crosslinking agents may include polycarboxylic acids such as citric acid and/or polyacrylic acids such as acrylic acid and maleic acid copolymers.

The distribution layer may generally have an average basis weight of 30 to 400 g/m ² , in particular 100 to 300 g/m ² . The density of the distribution layer can vary depending on the degree of compression of the article, but can be between 0.03 and 0.15 g/cm ³ , specifically 0.08 and 0.10 g/cm ³ measured at 0.30 psi (2.07 kPa).

The dry-laid fibrous structure may comprise a mixture of superabsorbent polymer (SAP) and dry-laid fibers 540 . Drylaid fibers 540 may include intrafiber crosslinked cellulosic fibers.

The absorbent article 20 can include a collar cuff 32 . The majority of the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 may be present at least in regions where the topsheet 24 in the topsheet/acquisition layer laminate 245 overlaps the acquisition layer 52 . Additionally, the majority of the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 may be present in the topsheet 24 and the acquisition layer 52 in regions extending parallel to the transverse axis 90 of the absorbent article 20 . The majority of the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 may be present in a region that extends parallel to the longitudinal axis 80 of the absorbent article 20, but does not extend beyond where the collar cuff 32 is attached. The area of the absorbent article 20 (specifically attached to the topsheet 24), as shown in Figures 2 or 3 . In that case, the majority of the three-dimensional protrusions 250 formed in the topsheet 24 of the topsheet/acquisition layer laminate 245 are formed from the fibers of the topsheet 24 .

Alternatively, the majority of the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 may be present in a region extending parallel to the transverse axis 90 of the absorbent article 20 such that the three-dimensional protrusions of the topsheet 24 are included. The upper region overlaps the acquisition layer 52. The length of the three-dimensional protrusion region of the topsheet/acquisition layer laminate 245 may be 5% to 60% or 10% to 40% wider than the length of the acquisition layer 52 of the topsheet/acquisition layer laminate 245 . The majority of the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 may extend in a region extending parallel to the longitudinal axis 80 of the absorbent article 20 such that the majority of the three-dimensional protrusions comprising the topsheet 24 The upper region overlaps the acquisition layer 52. The width of the region of the majority of three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 may be 5% to 60% or 10% to 40% wider than the width of the acquisition layer 52 of the topsheet/acquisition layer laminate 245. In that case, the majority of the three-dimensional protrusions 250 formed in the topsheet 24 of the topsheet/acquisition layer laminate 245 are formed from the fibers of the topsheet 24 .

In another alternative, the majority of the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 may only be present where the topsheet 24 in the topsheet/acquisition layer laminate 245 overlaps the acquisition layer 52, As shown in Figure 4.

Thus, the mostly three-dimensional protrusions 250 can provide an impression of depth and can support the caregiver's perception that the absorbent article 20 is well capable of absorbing liquid bodily exudates.

The majority of the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 may have a measured height of 0.3mm to 5mm or 0.5mm to 3mm or 1.0mm to 2.0mm according to the "Protrusion Height Test Method" as described below. Protrusion height.

The majority of the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 may have a thickness of 0.3 mm to 10 mm or 0.5 mm to 5 mm or 0.5 mm to 3.0 mm or 1.0 mm according to the "Protrusion Base Width Test Method" described below. The measured protrusion base width of the three-dimensional protrusion 250 of mm to 2.5 mm or 1.5 mm to 2.5 mm.

The mostly three-dimensional protrusions 250 having a shape including a specific height and width can provide an impression of depth and can support a caregiver's perception that the absorbent article 20 is well capable of absorbing liquid bodily exudates.

The absorbent article 20 includes an absorbent core 28 comprising an absorbent material 60 . The absorbent material 60 may comprise 80% to 100% SAP, such as SAP particles, based on the total weight of the absorbent material 60 .

Another type of absorbent material may be water-absorbent foams based on crosslinking monomers comprising acid groups, see eg EP 0 858 478 B1, WO 97/31971 A1, WO 99/44648 A1 and WO 00/52087 A1.

These three-dimensional protrusions 250 provide void volume to receive liquid bodily exudates. At the same time, the topsheet 24 and the acquisition layer 52 in the topsheet/acquisition layer laminate 245 can be in intimate contact because the topsheet 24 and the acquisition layer 52 are nested together. Additionally, the topsheet/acquisition layer laminate 245 is also in intimate contact with the underlying layer, distribution layer 54 . Thus, liquid body exudates are more efficiently transported from the topsheet/acquisition layer laminate 245 to the distribution layer 54, which maintains or even improves the dryness of the topsheet 24 of the topsheet/acquisition layer laminate 245. Rewet at the wearer's skin remains the same or even decreases. The topsheet/acquisition layer laminate 245 may also allow for more efficient use of the "airfelt-free" absorbent core 28. Overall, the topsheet 24 of the topsheet/acquisition layer laminate 245 has a similar or even improved dryness compared to the three-dimensional topsheet 24 placed over the acquisition layer 52 . Thus, an absorbent article 20 comprising an "airfelt-free" absorbent core and further comprising a topsheet/acquisition layer laminate 245 as described above can help retain liquids and provide storage space to acquire and absorb liquid bodily exudates.

The majority of three-dimensional protrusions 250 may include void areas 253 that do not contact the wearer's skin. The absorbent article 20 may contact the wearer's skin less than a flat topsheet. The void area 253 of the topsheet/acquisition layer laminate 245 can assist in the penetration of air between the wearer's skin and the topsheet/acquisition layer laminate 245 . Thus, the void region 253 of the topsheet/acquisition layer laminate 245 can improve the breathability of the topsheet/acquisition layer laminate 245 .

In addition to improving dryness, the void area 253 of the topsheet/acquisition layer laminate 245 may also allow feces to be absorbed and acquired within the void area. In such cases, the invention is suitable for absorbing faeces of relatively low viscosity.

The width of the acquisition layer 52 in a direction parallel to the transverse axis 90 is less than the width of the topsheet 24 in a direction parallel to the transverse axis 90 . If the width of the topsheet 24 and the acquisition layer 52 are the same, wicking of liquid bodily exudates under the collar cuff 32 may occur. As a result, liquid bodily exudates may not be properly absorbed by the absorbent core 28 , which causes the liquid bodily exudates to leak out of the absorbent article 20 . If the width of the acquisition layer 52 along the direction parallel to the transverse axis 90 is smaller than the width of the topsheet 24 along the direction parallel to the transverse axis 90, the acquisition layer 52 (which can receive liquid bodily exudates from the topsheet 24) can directly transport the liquid The body exudates are transported to the distribution layer 54 for subsequent absorption by the absorbent core 28 . Accordingly, liquid bodily exudates that are temporarily stored in the acquisition layer 52 of the topsheet/acquisition layer laminate 245 will not be easily drawn by capillary forces towards and beneath the collar cuff 32. Thus by making the width of the acquisition layer 52 smaller than the width of the topsheet 24 in the topsheet/acquisition layer laminate 245 in a direction parallel to the transverse axis 90, leakage can be reduced.

To help reduce leakage and rewet, the width of the acquisition layer 52 of the topsheet/acquisition layer laminate 245 along the direction parallel to the transverse axis 90 may be no more than 40% wider than the width of the distribution layer 54 and/or no wider than the width of the absorbent core 28 along the The width in a direction parallel to the transverse axis 90 is more than 20% wider. In such cases, liquid bodily exudates may not accumulate at or adjacent to the lateral edges of the acquisition layer. This prevents liquid bodily exudates from wicking underneath the collar hoop 32 . In fact, when the acquisition layer 52 of the topsheet/acquisition layer laminate 245 is no more than 20% wider than the width of the absorbent core 28, liquid body exudates can be easily transported into the absorbent core 28, which effectively transfers all exudates to the absorbent core 28. The fluid is drawn from the acquisition layer 52 into the absorbent core 28. This prevents liquid bodily exudates from wicking from the acquisition layer 52 to the underside of the grommet hoop 32 .

The acquisition layer 52 can receive liquid bodily exudates through the topsheet 24 and distribute them to the underlying absorbent layer. In such cases, the topsheet 24 in the topsheet/acquisition layer laminate 245 may be less hydrophilic than the acquisition layer 52 . The topsheet 24 of the topsheet/acquisition layer laminate 245 can be easily dewatered.

To enhance dehydration of the topsheet 24 of the topsheet/acquisition layer laminate 245, the pore size of the acquisition layer 52 can be reduced. To this end, the acquisition layer 52 may be made of fibers having a relatively small denier. Acquisition layer 52 may also have an increased density.

channel and channel opening

As noted above, as shown in Figure 7, when the absorbent material swells, the core wrap bond 27 remains attached, at least initially, in the region 26 that is substantially free of absorbent material. A channel 26' comprising a core wrap bond 27 is formed along the region 26 substantially free of absorbent material.

In the second stage, the core wrap bonds 27 in the channels 26' may begin to open to provide more room for the absorbent material 60 to swell while maintaining most of the benefits of the channels 26', such as the movement of the absorbent core 28 in the transverse direction. Increased flexibility and liquid body exudate management.

The strength of the core wrap bond 27 in the channel 26' may be lower than the strength of the bond used to attach a single substrate together or to attach two or more substrates together to form a core wrap . Thus, when the absorbent material 60 swells, the channels 26' open without any tearing of the core wrap.

The strength of the core wrap bond 27 within the channel 26' can be varied, for example, by varying the amount and nature of the adhesive used to attach the two sides of the core wrap, the pressure used to make the core wrap bond and/or the distribution of absorbent material 60, as more absorbent material 60 will generally result in more swelling and will put more pressure on the bond. The ductility of the material of the core wrap may also play a role.

In the third stage, corresponding to a very high saturation of the absorbent core 28, the core wrap bond 27 in the channel 26' can be opened further, optionally fully, to provide even More room to expand. Thus, the absorbent article 20 is fully loaded, ie the absorbent article 20 has reached its full capacity.

The consumer may notice that as the absorbent core 28 swells, channels 26' are formed. From the backsheet 25 of the absorbent article 20, the consumer can easily see the change in shape of the absorbent article 20 as it swells.

However, it is desirable to provide another signal to the consumer when the consumer views the absorbent article 20 from the topsheet 24 that the absorbent article 20 comprising an "airfelt-free" absorbent core absorbs well.

The topsheet/acquisition layer laminate 245 including the three-dimensional protrusions 250 may already provide an impression of depth and may support the caregiver's perception that the absorbent article 20 absorbs liquid bodily exudates well.

To enhance this impression of depth, the topsheet/acquisition layer laminate may include one or more regions 246 that are substantially free of three-dimensional protrusions.

The substantially three-dimensional protrusion-free region 246 may comprise less than 10%, specifically less than 5%, or less than 2% of the entire surface of the three-dimensional protrusion-free region.

If the region 246 substantially free of three-dimensional protrusions extends to either edge of the topsheet/acquisition layer laminate 245, each substantially three-dimensional protrusion-free region 246 may be substantially free of three-dimensional protrusions at each There are regions of three-dimensional protrusions 250 on either side of region 246 .

The portion of the topsheet 24 and the portion of the acquisition layer 52 of the topsheet/acquisition layer laminate 245 may be continuously attached together along a region 246 substantially free of three-dimensional protrusions. However, the one or more bonds may also be discontinuous (interrupted) along the region 246 substantially free of three-dimensional protrusions, such as a series of point bonds. The bond may be provided by known attachment methods such as adhesive bonding, pressure bonding, ultrasonic or thermal bonding, dynamic mechanical bonding or combinations thereof.

The attachment of the portion of the topsheet 24 and the portion of the acquisition layer 52 of the topsheet/acquisition layer laminate 245 may be provided by one or more adhesive materials.

For example, the attachment of the portion of the topsheet 24 and the portion of the acquisition layer 52 of the topsheet/acquisition layer laminate 245 may include a uniform continuous layer of adhesive, a patterned layer of adhesive, or a series of separate layers. Adhesive lines, adhesive spirals, or adhesive dots. Suitable attachment methods include open pattern networks of adhesive filaments as disclosed in US 4,573,986. Other suitable attachment methods include several adhesive filaments coiled in a helical pattern, as illustrated in the apparatus and methods shown in US3,911,173; US4,785,996; and US4,842,666. Adhesives manufactured by H.B. Fuller Company of St. Paul, Minnesota and sold as HL-1620 and HL1358-XZP have been found to be satisfactory.

The region substantially free of three-dimensional protrusions may have a length L' projected onto the longitudinal axis of the absorbent article which is at least 10% of the length L of the article. The region substantially free of three-dimensional protrusions may have a width of at least 2 mm, or at least 3 mm or at least 4 mm, at least 8 mm, at least 10 mm, up to, for example, 20 mm, or 16 mm or 12 mm along at least part of its length or along the entire length L' W'. The width of the region free of substantially three-dimensional protrusions may be constant over substantially the entire length of the region free of three-dimensional protrusions or may vary along its length.

Advantageously, said portion of the topsheet 24 of the topsheet/acquisition layer laminate 245 and said portion of the acquisition layer 52 can be attached by an adhesive at one or more regions 246 substantially free of three-dimensional protrusions Together, the adhesive comprises a plurality of adhesive lines substantially parallel to the longitudinal axis 80 of the absorbent article 20 . The plurality of adhesive lines may be provided by an adhesive slot device. The plurality of adhesive lines may represent the one or more bonds.

The following examples of shapes and sizes of regions 246 substantially free of three-dimensional protrusions are not limiting. A region 246 substantially free of three-dimensional protrusions may be present within the crotch region 37 of the absorbent article 20 . Specifically, the region 246 substantially free of three-dimensional protrusions may extend longitudinally parallel to the longitudinal axis 80 of the absorbent article 20 and/or extend laterally parallel to the transverse axis 90 of the absorbent article 20 . FIG. 8 shows as an example two longitudinally extending regions 246 substantially free of three-dimensional protrusions. The topsheet/acquisition layer laminate 245 may also include more than two regions 246 that are substantially free of three-dimensional protrusions, such as at least 3, or at least 4, or at least 5, or at least 6.

The topsheet/acquisition layer laminate 245 can include at least 2 regions 246 substantially free of three-dimensional protrusions that are symmetrically disposed on either side of the longitudinal axis 80 of the absorbent article 20 . Shorter regions 246 that are substantially free of three-dimensional protrusions may also be present, for example, in the rear region 38 or the front region 36 of the absorbent article 20 .

Regions 246 that are substantially free of three-dimensional protrusions can be at least partially oriented in the longitudinal direction of the absorbent article 20 . This generally means that each substantially three-dimensional protrusion-free region 246 extends more longitudinally than transversely, and generally at least twice as far longitudinally as transversely.

Region 246 substantially free of three-dimensional protrusions may be straight and oriented entirely longitudinally and parallel to longitudinal axis 80, but may also be curved or have one or more curved portions. In particular, some or all of these substantially three-dimensional protrusion-free regions 246, particularly those substantially three-dimensional protrusion-free regions 246 present in the crotch region 37, may be concave toward the longitudinal axis 80, as for example FIG. 8 is shown for a pair of regions 246 substantially free of three-dimensional protrusions. The radius of curvature can generally be at least equal to (and preferably at least 1.5 times or at least 2.0 times) the mean transverse dimension of the absorbent article 20; and can also be straight, but with a line parallel to the longitudinal axis 80 The formed (eg 5°) angle is up to 30°, or for example up to 20°, or up to 10°. The radius of curvature may be constant for each region 246 substantially free of three-dimensional protrusions, Or there may be variations along its length. This may also include an angled region 246 substantially free of three-dimensional protrusions therein, provided that the angle between two parts of the region 246 is at least 120°, preferably at least 150°. These substantially three-dimensional protrusion-free regions 246 may also branch, such as a central substantially three-dimensional protrusion-free region in the crotch region 37 superimposed with the longitudinal axis 80 toward the rear of the absorbent article 20 and/or towards the rear of the absorbent article 20. front branch.

Regions 246 that are substantially free of three-dimensional protrusions that coincide with the longitudinal axis 80 of the absorbent article 20 may be absent. When present in a symmetrical pair with respect to the longitudinal axis 80 of the absorbent article 20, the substantially three-dimensional protrusion-free regions 246 can be spaced apart from each other throughout their longitudinal extent. Generally, the minimum spacing may be, for example, at least 5 mm, or at least 10 mm, or at least 16 mm.

Furthermore, in order to reduce the risk of leakage of liquid bodily exudates, the region 246 substantially free of three-dimensional protrusions advantageously does not extend up to any edge of the topsheet/acquisition layer laminate 245, and specifically does not extend beyond the collar hoops therein. 32 is attached to the area of the absorbent article 20 . Typically, the minimum distance between the region 246 substantially free of three-dimensional protrusions and the nearest edge of the topsheet/acquisition layer laminate 245 is at least 5 mm.

At least one or more regions 246 of the topsheet/acquisition layer laminate 245 that are substantially free of three-dimensional protrusions can coincide with the one or more regions 26 of the absorbent core 28 that are substantially free of absorbent material.

The impression of depth is enhanced when the region 246 of the topsheet/acquisition layer laminate 245 substantially free of three-dimensional protrusions coincides with the one or more regions 26 of the absorbent core 28 substantially free of absorbent material. The caregiver can perceive that the absorbent article 20 absorbs liquid bodily exudates well.

carrier layer

The carrier layer 17 may be disposed between the topsheet/acquisition layer laminate 245 and the drylaid fibrous structure, as shown in Figures 11, 12A. Depending on the method used to prepare the three-dimensional structure of the topsheet/acquisition layer laminate 245, holes may be inadvertently created when the topsheet 24 and acquisition layer 52 are mechanically deformed together. When the distribution layer 54 comprises a dry-laid fibrous structure, the dry-laid fibers 540 of the dry-laid fibrous structure can pass through the unintentional holes formed at the topsheet/acquisition layer laminate 245, and Undesirable contact with the wearer's skin. The carrier layer 17 can act as a barrier layer to prevent the dry-laid fibers 540 of the dry-laid fibrous structure from passing through holes in the topsheet/acquisition layer laminate 245 that are inadvertently formed by the topsheet 24 together with the acquisition layer 52. formed by three-dimensional mechanical deformation, as shown in Figures 11 and 12A. Additionally, the carrier layer 17 can also assist in the transfer of liquid bodily exudates from the topsheet/acquisition layer laminate 245 to the drylaid fibrous structure.

The carrier layer 17 may include a first surface 171 and a second surface 172 . The second surface 172 of the carrier layer 17 may face the topsheet/acquisition layer laminate 245 . The first surface 171 of the carrier layer 17 may be attached to the absorbent core 28 at or adjacent to its longitudinal edges. Thus, when the carrier layer 17 is disposed between the topsheet/acquisition layer laminate 245 and the dry-laid fibrous structure, and the carrier layer 17 is attached to the absorbent core 28, the dry-laid fibers of the dry-laid fibrous structure 540 may not be able to escape between the carrier layer 17 and the absorbent core 28, as illustrated in Figure 12B. The attachment of the carrier layer 17 to the longitudinal edges of the absorbent core 28 may comprise a uniform continuous layer of adhesive 173, a discrete patterned application of adhesive or a series of individual lines, spirals or adhesive lines of adhesive. Mixture point.

Alternatively, the carrier layer 17 may be disposed between the dry-laid fibrous structure and the absorbent core 28, as shown in FIG. 13 . Thus, the carrier layer can help distribute and transfer liquid bodily exudates from the distribution layer 54 to the absorbent core 28, as shown in Figures 10 and 11, which allows for more efficient use of the absorbent core 28.

The carrier layer 17 may be attached to the first surface of the topsheet/acquisition layer laminate 245 at or adjacent its longitudinal edges. Thus, when the carrier layer 17 is disposed between the dry-laid fibrous structure and the absorbent core 28, and the carrier layer 17 is attached to the first surface of the topsheet/acquisition layer laminate 245, the dry-laid fibrous structure of the dry-laid fibrous structure The web-forming fibers 540 may not be able to escape between the topsheet/acquisition layer laminate 245 and the carrier layer 17 . The attachment of the carrier layer 17 to the longitudinal edges of the first surface of the topsheet/acquisition layer laminate 245 may comprise a uniform continuous layer of adhesive, a discrete patterned application of adhesive, or a series of individual lines of adhesive. , Adhesive Helix Or Adhesive Dots.

The length of the acquisition layer 52 of the topsheet/acquisition layer laminate 245 in a direction parallel to the longitudinal axis 80 may be less than the length of the topsheet 24 in a direction parallel to the longitudinal axis 80, as shown in FIG. When the length of the acquisition layer 52 of the topsheet/acquisition layer laminate 245 along the direction parallel to the longitudinal axis 80 is less than the length of the topsheet 24 along the direction parallel to the longitudinal axis 80, liquid body exudates cannot be easily absorbed The longitudinal edges 10, 12 of the article 20 suck, which reduces leakage.

The length of the acquisition layer 52 in the topsheet/acquisition layer laminate 245 may be less than the length of the absorbent core 28 in a direction parallel to the longitudinal axis 80, see eg FIG. 4 .

The acquisition layer 52 of the topsheet/acquisition layer laminate 245 can be positioned in the front region 36 of the absorbent article 20 and at least partially in the crotch region 37, as shown in FIG. 15 . In such cases, positioning the acquisition layer 52 of the topsheet/acquisition layer laminate 245 in the front region 36 of the absorbent article 20 facilitates the acquisition and distribution of liquid bodily exudates, such as urine, around the wearer's urine spot.

The acquisition layer 52 of the topsheet/acquisition layer laminate 245 can be positioned in the back region 38 of the absorbent article 20 and at least partially in the crotch region 37, as shown in FIG. 16 . Positioning the acquisition layer 52 of the topsheet/acquisition layer laminate 245 in the rear region 38 of the absorbent article 20 facilitates acquisition of the wearer's stool, especially when the stool has a low viscosity.

The majority of the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 may protrude toward the backsheet 25 or toward the body of the wearer when the absorbent article is in use.

The plurality of three-dimensional protrusions 250 may combine to form one or more graphics such as a logo, for example the PampersHeart logo. Having graphics supports the caregiver's perception that the absorbent article absorbs liquid body exudates well.

The topsheet/acquisition layer laminate 245 can be hypothetically divided into a first region and a second region. The first region may include a three-dimensional protrusion 250 protruding toward the backsheet 25 . The second region may comprise a three-dimensional protrusion 250 that protrudes towards the wearer's body when the absorbent article is in use.

For example, a first region may be located in the front region 36 of the absorbent article 20 and at least partially in the crotch region 37 , and a second region may be located in the back region 38 of the absorbent article 20 and at least partially in the crotch region 37 .

By having a first region where the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 protrude toward the backsheet 25, acquisition and absorption of liquid bodily exudates into the absorbent core 28 can be facilitated. By having a second region where the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 protrude towards the body of the wearer when the absorbent article is in use, the body's protection from such exudates can be improved. Thus, the combination of the first region and the second region may allow the absorbent article 20 to function better.

The topsheet 24 of the topsheet/acquisition layer laminate 245 may be coated with a lotion composition. The lotion composition may be located in the region of the topsheet 24 between the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 .

A typical lotion composition for use in diapers is disclosed in US Patent 6,426,444 B2. The resulting lotion composition can be applied to the topsheet/acquisition layer laminate by spraying, printing (e.g., flexographic printing), coating (e.g., contact slot coating, gravure coating), extrusion, microencapsulation chemical or a combination of these application techniques.

The majority of three-dimensional protrusions 250 may be disposed across the entire plan of the topsheet/acquisition layer laminate 245 in any suitable arrangement. Suitable arrangements include, but are not limited to: staggered arrangements, and zones. In some cases, the topsheet/acquisition layer laminate 245 may include both three-dimensional protrusions 250 and other features known in the art such as embossing and apertures. The three-dimensional protrusions 250 and other features may be in separate regions, intermingled or overlapping. The hybrid arrangement may be created in any suitable manner. In some cases, hybrid arrangements can be produced using techniques described in US Patent Publication US 2012/0064298A1 (Orr et al.). In other cases, the overlapping arrangement can be produced by forming the three-dimensional protrusions 250, then passing the topsheet/acquisition layer laminate 245 between the forming member with the convex forming elements thereon and the compliant surface, and Pressure is applied to the web with a forming member and a compliant surface. These techniques for producing overlapping arrangements allow three-dimensional protrusions 250 and other features to be combined so they are disposed in different locations on the topsheet/acquisition layer laminate 245, or they can result in three-dimensional protrusions 250 in different locations. At least some and at least some of the other features (apertures, embossing) are provided in the same location on the topsheet/acquisition layer laminate 245 .

Mechanically deformed parts and resulting three-dimensional protrusions

The topsheet/acquisition layer laminate 245 may be obtained by a process comprising the steps of: providing a first intermeshing roll 211 and a second intermeshing roll 212 as shown in Figures 17, 18A and 18B.

The first intermeshing roller 211 of the apparatus 200 may include a plurality of ridges 215 and corresponding grooves 216 extending substantially uninterrupted around the circumference of the first intermeshing roller 211 .

The second intermeshing roll 212 may include rows of circumferentially extending ridges and corresponding grooves 218 that have been modified into rows of circumferentially spaced teeth 217 spaced apart by The relationship extends around at least a portion of the second intermeshing roller 212 .

The topsheet 24 and the acquisition layer 52 can be intermeshed together between the first intermeshing roll 211 and the second intermeshing roll 212 such that the ridges 215 of the first intermeshing roll 211 extend to the grooves of the second intermeshing roll 212 218, and the teeth 217 of the second intermeshing roll 212 extend into the grooves 216 of the first intermeshing roll 211 to form the topsheet/acquisition layer laminate 245. Thus, a plurality of deformations including the three-dimensional protrusions 250 are obtained.

The three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 may be formed only at the locations where the topsheet 24 in the topsheet/acquisition layer laminate 245 overlaps the acquisition layer 52 .

The first intermeshing roller 211 and the second intermeshing roller 212 may be further defined by a tooth height TH, a pitch P, and an engagement depth E, as shown in FIG. 18A . The tooth height TH may be measured from the surface of the second intermeshing roller 212 to the tip of the tooth 217 . The tooth height TH may be in the range of 0.5mm to 10mm or 0.5mm to 5mm.

Pitch P may be defined as the tooth-to-tooth spacing measured from the tip of the first tooth of the second intermeshing roller 212 to the tip of the second tooth. The first and second teeth of the second intermeshing roller 212 may be located in the transverse direction. The pitch P may be in the range of 1 mm to 10 mm or 1 mm to 5 mm.

The depth of engagement E is a measure of the extent to which the first intermeshing roller 211 and the second intermeshing roller 212 are engaged with each other. The depth of engagement E can be measured from the top of the ridge 215 to the top of the tooth 217 which is laterally adjacent to the ridge 215 . The engagement depth E may be in the range of 0.5mm to 10mm or 0.5mm to 5mm or 1 to 4mm.

Each tooth 217 of the second intermeshing roller 212 may be defined by a circumferential tooth length TL and a tooth pitch TD, as shown in FIGS. 17 and 18B . The circumferential tooth length TL can be measured from the leading edge to the trailing edge at the tooth tip. The tooth length TL may be in the range of 0.5mm to 10mm or 0.5mm to 4mm or 1mm to 4mm.

Each tooth is circumferentially separated from one another by a pitch TD. The tooth distance TD may be measured from the leading edge of the first tooth to the trailing edge of the second tooth. The first and second teeth of the second intermeshing roller 212 may be on the same circumference in the longitudinal direction. The tooth pitch TD may be in the range of 0.5mm to 10mm or 0.5mm to 5mm or 1mm to 3mm.

Other orientations of the teeth 217, grooves 216, 218 and ridges 215 are possible, for example in the CD direction instead of the MD direction. The topsheet 24 and the acquisition layer laminate are nested together such that the three-dimensional protrusions formed in the topsheet coincide and fit together with the three-dimensional protrusions formed in the acquisition layer.

Both the topsheet 24 and the acquisition layer 52 may be extensible. The topsheet 24 and/or acquisition layer 52 are capable of stretching and do not interpenetrate through the corresponding ruptured topsheet or acquisition layer.

In general, the extensibility of the materials comprising the topsheet 24 and acquisition layer 52 can be selected based on the desired dimensions of the three-dimensional protrusions 250 . If a relatively large three-dimensional protrusion 250 is desired, a material with relatively high ductility will be selected.

For example, according to the "Test Method" as described in the "Definitions" section, the topsheet 24 or acquisition layer 52 can undergo a stress equal to or before reaching the breaking force along the longitudinal axis and/or transverse axis of the absorbent article. An apparent elongation of greater than at least 100% or 110% or 120% or 130% up to 200%.

In some instances, it may be desirable to have three-dimensional protrusions 250 that are larger along the longitudinal or transverse axis of the absorbent article 20 . To this end, the material making up the topsheet 24 and acquisition layer 52 may thus be more extensible along the longitudinal axis 80 of the absorbent article 20 than along the transverse axis 90, or vice versa.

The topsheet/acquisition layer laminate 245 may include a majority of three-dimensional protrusions 250 . The majority of three-dimensional protrusions 250 may protrude towards the distribution layer 54 (see also Fig. 2) or towards the carrier layer 17 (see Figs. 11, 12A). When the three-dimensional protrusions 250 extend toward the distribution layer 54, the contact area between the acquisition layer 52 of the topsheet/acquisition layer laminate 245 and the underlying distribution layer 54 is improved. Thus, the transfer of liquid bodily exudates from the topsheet/acquisition layer laminate 245 to the distribution layer 54 may be enhanced.

19A-19F illustrate different alternative forms of three-dimensional protrusions 250 . The annular protrusion may be a type of three-dimensional protrusion 250, see eg FIG. 19B. The annular protrusion may be obtained using the apparatus 200 by intermeshing process steps as described immediately above.

Another type of three-dimensional protrusion 250 may be a tunnel-shaped ring. In general, the tunnel-shaped ring may include a base forming an opening, and also include an opening at a leading edge 261 and an opening at a trailing edge 262, see eg FIG. 19C.

As shown in FIGS. 19A and 19B , the three-dimensional protrusion 250 in the form of an annular protrusion may include an inner three-dimensional protrusion 251A and an outer three-dimensional protrusion 251B. The inner three-dimensional protrusions 251A of the topsheet 24 are nested within the outer three-dimensional protrusions 251B of the acquisition layer 52 .

The three-dimensional protrusions 250 can be made by intermeshing the topsheet 24 and the acquisition layer 52 such that the inner three-dimensional protrusions 251A of the topsheet 24 and the outer three-dimensional protrusions 251B of the acquisition layer 52 overlap and fit together.

The inner three-dimensional protrusions 251A may comprise a plurality of looped fibers 254A of the topsheet 24 . The outer three-dimensional protrusion 251B into which the inner three-dimensional protrusion 251A is nested may comprise a plurality of annular fibers 254B of the acquisition layer 52 .

The three-dimensional protrusion 250 may include a void region 253, which is a portion of the three-dimensional protrusion 251A that does not include any fibers. The three-dimensional protrusion 250 may be defined by a base 256 forming an opening adjacent the topsheet 24 , a distal portion 257 , and one or more sidewalls 255 between the base 256 and the distal portion 257 . The three-dimensional protrusion 250 may be defined by a protrusion base width WL ₁ of the base 256 forming the opening as measured from two opposing sidewalls of the inner three-dimensional protrusion 251A at the base 256 . Each three-dimensional protrusion 250 may be defined by a width WL ₂ of void region 253 , which is the maximum width measured between two opposing sidewalls of inner three-dimensional protrusion 251A. The width WL ₂ of the void region 253 may be greater than the protrusion base width WL ₁ of the base 256 of the three-dimensional protrusion 250 . Dimensional measurements of protrusion base width WL ₁ of base 256 and width WL ₂ of distal portion 257 may be performed on photomicrographs. While the protrusion base width WL1 _of the base 256 is sized as specified herein, it should be understood that if the opening is not of uniform width along _a particular direction, the protrusion base width WL1 is measured at the widest portion. The three-dimensional protrusion 250 may have only one opening at the base 256 . The three-dimensional protrusions 250 may be formed from the fibers of the topsheet 24 and the acquisition layer 52 . Three-dimensional protrusion 250 may include a base 256 forming an opening, an opposing distal portion 257 , and one or more sidewalls 255 interposed between base 256 and distal portion 257 of three-dimensional protrusion 250 . Base 256 , distal portion 257 and one or more side walls 255 may be formed from fibers such that the three-dimensional protrusion has openings only at base 256 . At least 50% or at least 80% of the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 may have openings at the base 256 only. The three-dimensional protrusion 250 may have a tapered shape, see eg Fig. 19B.

As shown in FIG. 19C , each inner three-dimensional protrusion 251A and outer three-dimensional protrusion 251B can be made from a plurality of looped fibers 254A, 254B that are longitudinally and transversely aligned with each other to create a tunnel-shaped loop 250. , the tunnel-shaped ring has openings 261 , 262 on each end of the tunnel in addition to the opening at the base 256 . In this case, the protrusion base width WL1 of the base 256 is relatively small. The protrusion base width WL ₁ of the base 256 of the three-dimensional protrusion 250 may be in the range of 0.1 mm to 1.2 mm, or 0.1 mm to 1 mm, or 0.1 mm to 0.5 mm.

In the region of three-dimensional protrusions, the topsheet 24 and/or acquisition layer 52 may include one or more discontinuities. The formation of the one or more discontinuities may be due to the properties of the topsheet 24 and acquisition layer 52 . The topsheet 24 may be less extensible with respect to fiber mobility and/or fiber extensibility in the acquisition layer 52, or vice versa, so that holes begin to form in the topsheet 24 and/or the acquisition layer 52.

Accordingly, the acquisition layer 52 may be interrupted in the region of the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245, as shown in Figure 19D or 19E. The three-dimensional protrusions 251B of the interrupted acquisition layer 52 may include interruptions 258 .

In general, the acquisition layer 52 may have a lower extensibility than the topsheet 24 . In such cases, the acquisition layer 52 may begin to rupture and form discontinuities, ie, the fibers making up the acquisition layer 52 are less extensible and/or less mobile than the fibers making up the topsheet 24 .

The three-dimensional protrusions 251A of the uninterrupted topsheet 24 can overlap and bond together the three-dimensional protrusions 251B of the interrupted acquisition layer, as shown in FIG. 19D. In other words, the topsheet 24 is not pushed through the acquisition layer 52 such that the topsheet 24 does not interpenetrate the acquisition layer 52 .

Alternatively, the three-dimensional protrusions 251A of the uninterrupted topsheet 24 may be partially bonded to the three-dimensional protrusions 251B of the interrupted acquisition layer, as shown in Figure 19E.

Likewise, the topsheet 24 may be interrupted in the region of the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 .

In general, the topsheet 24 may have a lower extensibility than the acquisition layer 52 . In such cases, the topsheet 24 may begin to rupture and form discontinuities, ie, the fibers making up the topsheet 24 may be less extensible and/or less mobile than the fibers making up the acquisition layer 52 .

In another alternative, the topsheet 24 and acquisition layer 52 may be interrupted in the area of the three-dimensional raised portion 250 of the topsheet/acquisition layer laminate 245, and the three-dimensional raised portion 251A of the topsheet is separated from the three-dimensional raised portion 251A of the acquisition layer 52. The protrusions 251B are overlapped and bonded together. The discontinuity 258A in the topsheet 24 in the area of the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 will not coincide with the acquisition layer 52 in the area of the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245. The discontinuity 258B of , as shown in FIG. 19F .

The plurality of three-dimensional protrusions 250 may protrude towards the body of the wearer when the absorbent article 20 is in use (see also FIG. 3 ). As the three-dimensional protrusions 250 protrude toward the wearer's body (when the absorbent article 20 is in use), the contact area between the topsheet 24 of the topsheet/acquisition layer laminate 245 and the wearer's skin is enhanced. Thus, the topsheet/acquisition layer laminate 245 provides cushioning and improved comfort to the wearer.

FIGS. 20A-20D show alternatives illustrating how a plurality of three-dimensional protrusions 250 , such as annular protrusions, may protrude from the acquisition layer 52 to the topsheet 24 of a topsheet/acquisition layer laminate 245 . In those alternatives, the three-dimensional protrusion 250 in the form of an annular protrusion may include an inner three-dimensional protrusion 251A and an outer three-dimensional protrusion 251B. The inner three-dimensional protrusions 251A of the acquisition layer 52 are nested within the outer three-dimensional protrusions 251B of the topsheet 24 . The inner three-dimensional protrusion 251A may include a plurality of annular fibers 254B of the acquisition layer 52 . The outer three-dimensional protrusions 251B (within which the inner three-dimensional protrusions 251A are nested) may comprise a plurality of looped fibers 254A of the topsheet 24 .

A 10 cm ² area of the topsheet/acquisition layer laminate 245 may include 5 to 100 three-dimensional protrusions 250 , 10 to 50 three-dimensional protrusions 250 or 20 to 40 three-dimensional protrusions 250 .

Precursor materials for topsheet and acquisition layer

The topsheet/acquisition layer laminate 245 of the present invention can be made from any suitable nonwoven material ("precursor material"). In some cases, the topsheet/acquisition layer laminate 245 may also be free of cellulosic material. The precursor material for the topsheet/acquisition layer laminate 245 may have suitable properties to be deformed. Suitable properties of the precursor material may include apparent elongation of the fibers, fiber mobility, deformation and stretchability in the region in which the three-dimensional protrusions 250 of the topsheet/acquisition layer laminate 245 are formed. Thus, the precursor material is capable of undergoing mechanical deformation to ensure that the three-dimensional protrusions 250 will not tend to revert or return to the previous configuration of the flat topsheet 24 laminated on the flat acquisition layer 52 .

Several examples of nonwoven materials suitable for use as the topsheet 24 of the topsheet/acquisition layer laminate 245 may include, but are not limited to: spunbond nonwovens; carded nonwovens; Deformed nonwovens.

One nonwoven suitable for use as the topsheet 24 of the topsheet/acquisition layer laminate 245 may be an extensible polypropylene/polyethylene spunbond nonwoven. One suitable nonwoven material for use as the topsheet 24 of the topsheet/acquisition layer laminate 245 can be a spunbond nonwoven including polypropylene and polyethylene. Fibers may comprise blends of polypropylene and polyethylene. Alternatively, the fibers may comprise bicomponent fibers such as sheath-core fibers with polyethylene in the sheath of the fiber and polypropylene in the core of the fiber.

The topsheet 24 of the topsheet/acquisition layer laminate 245 may have a basis weight of 8 to 40 gsm, or 8 to 30 gsm, or 8 to 20 gsm.

Suitable nonwoven materials for the acquisition layer 52 of the topsheet/acquisition layer laminate 245 may include, but are not limited to: spunbond nonwovens, air through bonded ("TAB") carded high loft nonwovens, spunlace nonwovens materials, hydrowoven nonwovens, and resin bonded carded nonwovens.

Spunbond PET can be denser than carded nonwovens, providing greater uniformity and opacity. Since PET fibers are not very extensible, nonwovens can be bonded such that when the material is strained at least some of the fibers can be easily separated from the bond sites to allow the fibers to be pulled out of the Glue the parts and rearrange. This type of bonding, such as pressure bonding, can help increase the level of fiber movement. In fact, the fibers tend to pull out of the bond site under tension.

The acquisition layer exhibits a basis weight of 10 to 120 gsm, or 10 to 100 gsm, or 10 to 80 gsm.

The topsheet 24 and/or the acquisition layer 52 may have a density of 0.01 to 0.4 g/cm ³ or 0.01 to 0.25 g/cm ³ or 0.04 to 0.15 g/cm ³ .

The topsheet 24 and acquisition layer 52 may be joined together prior to or during mechanical deformation. If desired, adhesives, chemical bonding, resin or powder bonding, or thermal bonding can optionally be used between the topsheet 24 and the acquisition layer 52 to bond certain areas or regions of the topsheet 24 and the acquisition layer 52. All glued together. Additionally, the topsheet 24 and acquisition layer 52 may also be bonded during processing, for example, by carding the topsheet 24 onto the acquisition layer 52 and thermal thermal bonding the combined layers.

The topsheet 24 may be attached to the acquisition layer 52 prior to any mechanical deformation. For example, the topsheet 24 may be attached to the acquisition layer 52 at locations where the topsheet 24 and the acquisition layer 52 overlap. Attachment of the topsheet 24 to the acquisition layer 52 may include a uniform continuous layer of adhesive, a discontinuous patterned application of adhesive, or a series of individual lines, spirals, or dots of adhesive. The basis weight of the adhesive in the topsheet/acquisition layer laminate 245 can be from 0.5 to 30 gsm or from 1 to 10 gsm or from 2 to 5 gsm.

Materials for the carrier layer

The carrier layer 17 may be selected from the group consisting of: nonwoven, tissue, or film, and combinations thereof.

Examples of nonwoven webs for the carrier layer 17 may include various types of known nonwoven webs such as spunbond nonwoven webs, meltblown nonwoven webs, spunbond-meltblown-spunbond nonwovens web. These nonwoven webs are made from thermoplastic polymers.

The materials used to make up the fibers of the nonwoven web used for the carrier layer 17 may include various types of known fibers such as polyethylene, polypropylene, polyester, and acryl conjugate fibers such as polyethylene/polypropylene, Polyethylene/polyethylene terephthalate, and polypropylene/polyethylene terephthalate, that is, fibers formed of core-sheath fibers and side-by-side fibers. Fibers can be used alone or in combination. In addition, the carrier layer 17 may also have a single-layer structure or a multi-layer structure.

The carrier layer 17 may comprise tissue paper made of wet-laid fibers including cellulosic fibers having a "Wet Burst Strength" of 50 to 500 g according to the "Wet Burst Strength Test Method" and their The combination.

The carrier layer 17 may be treated with a surfactant to render the carrier layer 17 hydrophilic. The carrier layer 17 may be made of a material from the group described above which has been chemically modified to render it hydrophilic. The hydrophilic carrier layer 17 can thus improve the transfer of liquid bodily exudates from the distribution layer 54 to the absorbent core 28 of the absorbent article 20 .

The carrier layer 17 may have a basis weight of at least 5 to 60 gsm, or at least 5 to 20 gsm, or at least 5 to 15 gsm.

The carrier layer 17 may be wider and longer than the distribution layer 54 . When the distribution layer 54 includes dry-laid fibers 540, and if the topsheet/acquisition layer laminate 245 includes holes, the carrier layer can help prevent the dry-laid fibers 540 from contacting the wearer's skin.

The carrier layer 17 may be colored. Color can be imparted to the carrier layer 17 by pigmentation. The term "pigmented" includes any pigment suitable for imparting a non-white color to carrier layer 17 . The term therefore excludes "white" pigments such as _TiO2 , which are commonly added to the layers of conventional absorbent articles to give them a white appearance. Pigments are typically dispersed in a vehicle or substrate when applied, for example, as in inks, paints, plastics or other polymeric materials.

The pigments can be incorporated, for example, into polypropylene masterbatches. Masterbatches include high concentrations of pigments and/or additives dispersed in a carrier medium which can then be used to color or modify natural polymeric materials into colored two-component nonwoven materials. An example of a suitable color masterbatch material that can be incorporated is Pantone Color 270 Sanylen violet PP 42000634 ex Clariant, which is a PP resin with a high concentration of violet pigment. Typically, the amount of pigment incorporated may range from 0.3% to 2.5% by weight of carrier layer 17 .

Alternatively, color may be imparted to carrier layer 17 by impregnating a colorant into the substrate. Colorants such as dyes, pigments or combinations may be impregnated in the formation of substrates such as polymers, resins or nonwovens. For example, the colorant may be added to the molten batch of polymer during film, fiber or filament formation.

When viewing the absorbent article from the topsheet, the colored carrier layer 17 can provide the caregiver with an enhanced impression of depth to support such an impression imparted by the three-dimensional protrusions 250, so long as the colored carrier layer 17 is visible from the topsheet 24. Thus, the colored carrier layer 17 can support the caregiver's perception that liquid body exudates are well absorbed by the absorbent article.

For the same reason, the topsheet 24 and/or the acquisition layer 52 of the topsheet/acquisition layer laminate 245 may be colored.

The carrier layer 17 may be porous, may have a relatively high permeability, and have a relatively high saturation level when exposed to fluid under a suction pressure of, for example, 20 cm of water. The relatively high saturation level of the carrier layer 17 may be defined as the ratio between the volume of liquid bodily exudates in the pores of the carrier layer 17 and the total void volume of the carrier layer 17 . The carrier layer 17 can help provide connectivity between the acquisition layer 52 and the distribution layer 54 of the topsheet/acquisition layer laminate 245 .

In addition, the carrier layer 17 may also include holes of relatively small size such that the dry-laid fibers 540 of the dry-laid fibrous structure of the distribution layer 54 may partially pass through the holes of the carrier layer. Thus, the dry-laid fibers 540 of the dry-laid fibrous structure can be woven and contact the acquisition layer 52 of the topsheet/acquisition layer laminate 245 . The carrier layer 17 may comprise holes having a size of 0.02 mm to 10 mm.

Example

The topsheet and acquisition layer were attached to each other with a hot melt adhesive applied in a spiral at a basis weight of 5 gsm. The acquisition layer was centered onto the topsheet relative to the topsheet and placed 50mm from the front MD edge of the topsheet. The topsheet and acquisition layer are attached together to form a composite web.

The topsheet and acquisition layer attached together have been mechanically deformed simultaneously by passing them between a pair of intermeshing rollers 211, 212, see eg Fig. 17 . The topsheet of the topsheet/acquisition layer laminate contacts a first intermeshing roll 211 . The acquisition layer of the topsheet/acquisition layer laminate contacts the second intermeshing roll 212 . The ridges and grooves have triangular shaped cross-sections, as illustrated in Figure 18A. The pitch P of the rollers was 0.100 inches (2.5 mm). The second intermeshing roller 212 has discrete teeth 217 arranged in a staggered pattern. Teeth 217 have a uniform circumferential length dimension TL of approximately 0.195 inches (4.9 mm), are uniformly spaced circumferentially from each other by a distance TD of 0.162 inches (4.1 mm), and have a tooth height TH of approximately 0.270 inches (10.6 mm). The long side of the tooth has a sidewall angle of about 5 degrees from vertical, and the leading and trailing edges of the tooth have vertical sidewalls. The first intermeshing roll 211 has a continuous ridge 215 with a height of about 0.270 inches (10.6 mm). The topsheet attached to the acquisition layer was intermeshed between the first intermeshing roll 211 and the second intermeshing roll 212 at a depth of engagement (DOE) of 0.135 inches (3.43 mm).

The topsheet of the topsheet/acquisition layer laminate was a hydrophilic coated monocomponent high elongation spunbond polypropylene (HES PP) nonwoven having a density of 0.11 g/ ^cm3 . The one-component HES PP nonwoven used for the topsheet had an overall basis weight of 20 gsm. The one-component HES PP nonwoven was first coated with a topcoat made of fatty acid polyethylene glycol ester in order to produce a permanently hydrophilic one-component HES PP nonwoven. The topsheet of the topsheet/acquisition layer laminate had a width of 168mm and a length of 488mm.

The acquisition layer of the topsheet/acquisition layer laminate was a spunbond nonwoven having a basis weight of 60 gsm and a density of 0.13 g/ ^cm3 . The acquisition layer comprised surfactant-treated 7 denier PET/coPET (polyethylene terephthalate) trilobal bicomponent fibers with a PET/coPET ratio of 70/30. The acquisition layer of the topsheet/acquisition layer laminate had a width of 90 mm and a length of 338 mm.

The carrier layer was a coPET/PET pointed trilobal bicomponent fiber with a PET/coPET ratio of 90/10. The basis weight of the carrier layer was 17.7 gsm. The carrier layer has a width of 168 mm and a length of 250 mm.

Prototype diapers used in the examples

The diaper prototypes used in the above examples were prepared using Pampers Premium Care S4 (size 4) diapers commercially available in Russia from October 2011 to October 2012. A Pampers Premium Care S4 (size 4) diaper comprised a topsheet, an acquisition layer below the topsheet, a distribution layer below the acquisition layer, an absorbent core between the acquisition layer and the backsheet below the absorbent core. The diaper prototypes used in the above examples were prepared using Pampers Premium Care S4 (size 4) diapers.

The topsheet and acquisition layer attached together for each example were placed on top of a Pampers Premium CareS4 (size 4) diaper from which the commercial topsheet and acquisition layer had been removed, keeping the distribution layer in between. in situ. For each diaper prototype based on the above examples, the topsheet/acquisition layer laminate was placed on top of the distribution layer with the three-dimensional protrusions protruding towards the backsheet.

A hot melt adhesive in the form of a spiral was applied at a basis weight of 5 gsm on the surface of the carrier layer facing the acquisition layer of the topsheet/acquisition layer laminate. The front edge of the acquisition layer was placed 10 mm from the front edge of the distribution layer. The topsheet/acquisition layer laminate attached to the carrier layer is attached to the distribution layer and the absorbent core with a hot melt adhesive applied to one side of the carrier layer and the topsheet facing the distribution layer. on the whole side. The hot melt adhesive was applied in a helix at a basis weight of 5 gsm.

The three-dimensional protrusions of the topsheet/acquisition layer laminate protrude toward the backsheet as the topsheet of the topsheet/acquisition layer laminate contacts the convex roller, as described above.

Each prototype diaper was compacted in the bag at the "in-bag stack height" (ie 10 bifold diapers with a total thickness of 90 mm) for 1 week. The bags were then opened and the diapers removed from the bags were conditioned at 23°C +/- 2°C and 50% +/- 10% relative humidity (RH) for at least 24 hours before any testing was performed.

The measured protrusion height and the measured protrusion base width of the three-dimensional protrusions of the topsheet/acquisition layer laminates were measured according to the respective "Test Method for Lug Height" and "Test Method for Lump Base Width" (Table 1) .

Table 1: Measurements of protrusion height and protrusion base width for three-dimensional protrusions

parallel assay Measured protrusion height (mm) Measured Protrusion Base Width (mm) average value 1.40 2.00 standard deviation 0.0 0.1

Test Methods

Wet Burst Test Method

As used herein, "wet burst strength" is a measure of the ability of a fibrous structure to absorb energy when wetted and subjected to deformation relative to the plane of the fibrous structure.

The wet burst strength of the fibrous structure (referred to within this test method as a "specimen") is determined using an electronic burst tester and specified test conditions. The results obtained from 4 experiments were averaged and the wet burst strength was recorded for the fibrous structure 55 consisting of a single wet-laid fibrous layer.

equipment

- Equipment: Burst Tester - Thwing-Albert Vantage Burst Tester or equivalent ball burst tester where the ball moves downward during the test. See manufacturer's operating and setting instructions. The ball diameter is 1.59 cm and the clamp opening diameter is 8.9 cm.

- Calibration weights - see manufacturer's calibration instructions.

- For laboratory testing, control the conditioning room temperature and humidity within the following limits:

Temperature: 23°±1°C

Relative humidity: 50%±2%

- Paper knife - cutting board, 600mm size

- Scissors - 100mm or larger

- Disc - Approximate width/length/depth: 240 x 300 x 50mm, or equivalent

- Distilled water at the temperature of the conditioning chamber used

sample preparation

The fibrous structure 55 can be unwound from the roll.

The samples to be tested were conditioned in the conditioning room for 24 hours immediately prior to testing. All tests were performed in a conditioning room.

The samples were cut such that they were about 228mm in length and about 140mm in width.

operate

The Burst Tester instrument was set up and calibrated according to the manufacturer's instructions for the instrument used.

Grasp the sample by its narrow edge and dip the center of the sample into a pan filled with distilled water (about 25 mm from the top). Allow the samples to stand in the water for 4 (±0.5) seconds.

Hold the sample in an upright position while draining excess water from the sample for 3 (±0.5) seconds.

The test should be performed immediately after the draining step. The samples should have no punctures, tears or defects in the area of the sample to be tested. If there is a puncture, tear or defect, the test is restarted.

The sample is placed between the upper and lower rings of the Burst Tester instrument. The sample is centered and positioned flat on the lower ring of the sample holder in such a way that there is no slack in the sample.

Lower the upper ring of the pneumatic holder to secure the sample.

start testing. The test ends when the sample fails (cracks), ie when the load drops 20 g from the peak force. Record the maximum force.

The plunger will automatically back up and return to its original position.

Lift the upper ring to remove and discard the tested sample.

This procedure was repeated until all replicas were tested.

calculate

Wet Burst Strength = Sum of Peak Load Readings/Number of Replicas Tested

Record wet rupture results to the nearest gram.

Protrusion Base Width Test Method and Protrusion Height Test Method

1) General information

The "measured protrusion base width" and "measured protrusion height" of the three-dimensional protrusions of the topsheet/acquisition layer laminate of the absorbent article were obtained using commercially available from GFMesstechnik GmbH (Warthestra βe 21, D14513 Teltow/Berlin, Germany) Measured by the GFM Primos Optical Profiler instrument. Alternative suitable non-contact surface topographers with similar measurement and analysis principles may also be used, GFMPrimos is exemplified here.

The GFM Primos Optical Profiler instrument includes a compact optical measurement sensor based on digital micromirror projection, which consists of the following main components:

a) DMD projector with 800×600 direct digitally controlled micromirror

b) CCD camera with high resolution (640×480 pixels)

c) Projection optics suitable for measuring an area of at least 30 x 40mm

d) Recording optics suitable for measuring an area of at least 30 x 40 mm

e) Bench tripod based on small hard stone slabs

f) cold light source (one suitable unit is the KL 1500 LCD, Schott North America, Inc. (Southbridge, MA))

g) Measurement, control, and evaluation computer running ODSCAD 6.3 software

Turn on the cold light source. Set the setting on the cold light source to provide a color temperature of at least 2800K.

Turn on the computer, monitor, and open the image acquisition/analysis software. In the Primos Optical Profiler instrument, select the "Start Measurement" icon from the ODSCAD 6.3 task bar, then click the "Live Image" button.

Calibration plates were used to calibrate the instrument in lateral (X-Y) and vertical (Z) dimensions according to the manufacturer's instructions. Such "calibration" is performed using a rigid solid plate of any matte material having a length of 11 cm, a width of 8 cm and a height of 1 cm. The plate has grooves or machined channels with a rectangular cross-section, a length of 11 cm, a width of 6.000 mm and a precise depth of 2.940 mm. The groove is parallel to the length of the plate. After calibration, the instrument must be able to measure the groove's width and depth dimensions to an accuracy of ±0.004 mm.

All tests were performed in a conditioned room maintained at 23±2°C and 50+/−10% relative humidity. The surface to be measured can be lightly sprayed with a very fine white powder spray. Preferably, the spraying agent is NORD-TEST Developer U 89 available from Helling GmbH (Heidgraben, Germany).

2) Method for measuring the width of the base of the protrusion

Extract the topsheet/acquisition layer laminate from the absorbent article by attaching the absorbent article to a flat surface in a tensioned planar (i.e. stretched planar) configuration such that the topsheet of the topsheet/acquisition layer laminate up. Cut away any leg elastics or cuff elastics to allow the absorbent article to lay flat. Using scissors, make two longitudinal incisions through all layers above the absorbent core (ie core wrap) along the edge of the topsheet/acquisition layer laminate. Two transverse cuts are made through the same layer along the front and back waist edges of the absorbent article.

The topsheet/acquisition layer laminate and any other layers above the absorbent core are then removed without disturbing the topsheet/acquisition layer laminate. A freeze spray such as CRC Freeze Spray manufactured by CRC Industries, Inc. (885 Louis Drive, Warminster, PA 18974, USA) or an equivalent aid may be used to facilitate removal of the uppermost layer from the absorbent article. The topsheet/acquisition layer laminate is then separated from any other layers, including any carrier layers (eg, nonwoven carrier layer, tissue layer); if necessary, using a freeze spray. If a distribution layer such as a pulp-containing layer is attached to the topsheet/acquisition layer laminate, carefully remove any remaining cellulose fibers with tweezers without altering the acquisition layer.

Lay the topsheet/acquisition layer laminate (conditioned for at least 24 hours at a temperature of 23°C ± 2°C and a relative humidity of 50% ± 10%) with three-dimensional protrusions, the "sample", on a rigid flat level Apparently, the body facing side is up, ie the topsheet of the topsheet/acquisition layer laminate is facing up. Make sure the sample is placed in a flat configuration and not stretched so that the sample is uncovered.

A nominal external pressure of 1.86 kPa (0.27 psi) was then applied to the sample. Such nominal external pressure is applied without interfering with the profile measurement. This external pressure is achieved using a transparent matte flat Applied with a board measuring 200mm by 70mm and a suitable thickness (approximately 5mm) to achieve a weight of 83g. Gently place the plate on top of the sample so that The center point of the plate is at least 40 mm away from any folds, allowing the entire plate to rest on the specimen. A fold corresponds to that portion of an absorbent article (eg a topsheet/acquisition layer laminate) where the absorbent article has been folded for packaging purposes.

Two 50mm x 70mm metal weights (each having a mass of 1200g (approximate thickness of 43mm)) were gently placed on the board so that the 70mm edge of each metal weight is aligned with The 70mm edges of the boards are aligned. A metal cabinet frame with external dimensions of 70mm x 80mm and internal dimensions of 42mm x 61mm and a total weight of 142g (approximate thickness of 6mm) was positioned between the two end weights center of the board, aligning the longest side of the frame with the longest side of the board.

If the sample is smaller than 70 x 200 mm, or if there is no sufficiently large area without folds, or if the region of interest is close to the edge of the sample and cannot be analyzed with the above Plexiglas and weight settings, then The XY scale of the plate and the added metal weights can be adjusted to achieve a nominal external pressure of 1.86kPa (0.27psi) while maintaining a minimum 30x40mm field of view. At least 10 complete three-dimensional protrusions of the sample should be captured in the 30mm x 40mm field of view.

Position the projection head normal to the sample surface (ie normal to the topsheet of the topsheet/acquisition layer laminate).

Adjust the distance between the sample and projection head for optimal focus.

In the Primos Optical Profiler instrument, turn on the button "Pattern" so that a red cross appears on the screen cross and a black cross appears on the sample.

Adjust the focus control until the black cross is aligned with the red cross on the screen.

Adjust image brightness, then "capture" the digitized image.

In the Primos Optical Profiler instrument, the hole in the lens is changed through a hole in the side of the projector head and/or by changing the camera "gain" setting on the screen.

When the lighting is optimal, the red circle marked "I.O." at the bottom of the screen will turn green.

Click the "Measure" button.

The topography of the upper surface of the topsheet/acquisition layer laminate samples was measured through the Plexiglas plate over the entire field of view of 30mm x 40mm. It is important to keep the sample still during this time in order to avoid blurring of the captured image. Images should be captured within 30 seconds of placing the Plexiglas plate, metal weights and racks on top of the sample.

After the image was captured, the X-Y-Z coordinates of each pixel of the 40mm x 30mm field of view area were recorded. The X direction is a direction parallel to the longest edge of the rectangular field of view, and the Y direction is a direction parallel to the shortest edge of the rectangular field of view. The Z direction is a direction perpendicular to the X-Y plane. The X-Y plane is horizontal, and the Z direction is vertical, ie, orthogonal to the X-Y plane.

The data were flattened and filtered using a polynomial filter (n=6), an 11 pixel by 11 pixel median filter, and an 81 pixel by 81 pixel structural filter. A polynomial filter (n=6) approximates the X-Y-Z coordinate surface with a polynomial of degree 6 and returns the difference to the approximated polynomial. The 11 pixel by 11 pixel median filter divides the field of view (40mm x 30mm) into 11 pixel by 11 pixel X-Y squares. The Z coordinate of a pixel located at the center of a given 11 pixel by 11 pixel square will be replaced by the average Z value of all pixels of that given square. An 81 pixel by 81 pixel structure filter removes the fluctuations of the structure and translates all Z peaks belonging to the bottom surface of the Plexiglas plate to the top X-Y plane.

The "reference plane" is thus defined as the X-Y plane that intercepts the topography profile for the entire field of view (ie 30mm x 40mm) 100 microns below the top X-Y plane. In the Primos Optical Profiler instrument, to measure the "material area" of the "reference plane" (Z=-0.1 mm), click on the button "Evaluate". Then, use the "Filter" function to apply pre-filtering routines, which include polynomial filters (n=6), 11 by 11 median filters, and structural filters (n=81). Save the image to a computer file with the extension ".omc".

Perform the same above procedure for the topsheet/acquisition layer laminate so that the garment facing side is up (i.e. the acquisition layer of the topsheet/acquisition layer laminate is facing up) and the 40mm x 30mm field of view is at the exact topsheet/acquisition layer At the same X-Y position of the laminate.

The "empty area" of the datum plane may be defined as the area of the "datum plane" above the surface profile. A "void region" with a boundary strictly inside the field area (i.e. 30mm x 40mm) without intersecting or overlapping the border of the field area (ie 40mm x 30mm) is defined as an "isolated void region" . For "isolated voids", the measured protrusion base width is defined as the diameter of the largest circle that can be inscribed within a given "isolated void". The circle should only overlap the "isolated empty area".

In the Primos Optical Profiler instrument, this can be done by clicking on "Draw circle" and drawing the largest possible inscribed circle within the selected "isolated empty area". Click on "Show sectional picture" and measure the diameter of the circle to obtain the protrusion base width by clicking on the end of the profile of the sectional picture and then clicking on "Horizontal distance".

For the acquired and digitized images, determine the protrusion base width for all "isolated empty areas". Then, the "measured protrusion base width" was calculated as the arithmetic mean of the 6 largest protrusion base widths.

3) Method of measuring protrusion height

The topsheet/acquisition layer laminate was extracted from the absorbent article as described above in the "Protrusion Base Width Test Method".

Then conditioned and scanned under a pressure of 1.86 kPa (0.27 psi) a sample of the topsheet/acquisition layer laminate comprising three-dimensional protrusions with the body facing side up, i.e. the topsheet of the topsheet/acquisition layer laminate facing up, as above Described in the Protrusion Base Width Test Method.

After the image was captured, the X-Y-Z coordinates of each pixel of the 40mm x 30mm field of view area were recorded and flattened/filtered as described above in the "Protrusion Base Width Test Method". The reference plane is also defined as the reference plane described above in the "Protrusion Base Width Test Method".

In the Primos Optical Profiler instrument, to measure the "material area" of the "reference plane" (Z=-0.1 mm), click on the button "Evaluate". The "Filter" function was then used to apply pre-filtering routines, which included polynomial filters (n=6), 11 by 11 median filters, and structural filters (n=81). Save the image to a computer file with the extension ".omc".

The topsheet/acquisition layer laminate is then subjected to the same procedure described above in the "Test Method for Raspberry Base Width" with the garment-facing side up (i.e. the acquisition layer of the topsheet/acquisition layer laminate is facing up), the resulting The 40mm x 30mm field of view is at the exact same X-Y position of the topsheet/acquisition layer laminate.

The "empty area" of the datum plane may be defined as the area of the "datum plane" above the surface profile. A "void area" having a boundary strictly inside the field area (i.e. 30mm x 40mm) without intersecting or overlapping the border of the field area (ie 40mm x 30mm) is defined as an "isolation void area" ". For an "Isolation Void Area", the "Protrusion Height" is defined as the minimum Z value of the point of the topsheet/acquisition layer laminate surface profile with X-Y coordinates located in this "Isolation Void Area" and the Z value of the top X-Y plane the distance between.

Click on "Draw N parallel lines" and draw the first line segment parallel to the X-axis of the field of view (the direction of the longest dimension of the field of view) , passing through the center of the Isolation Empty Region and extending beyond the boundaries of the Isolation Empty Region. The center of the "isolation void" corresponds to the middle of the line segment parallel to the Y-axis of the field of view and joining the maximum and minimum Y values of the "isolation void". Then enter the "number" of the lines to be drawn, and set the "distance" between the lines to 0.05mm. Enough lines need to be drawn to cover the entire "isolation void". Set the averaging parameter to 0 and click "Ok". Then click "Show sectional picture". Click on the point of the profile with the smallest Z value and click on "Vertical distance" to get the protrusion height.

For the acquired and digitized images, determine the "Protrusion Height" of all "Isolated Empty Areas". The measured protrusion heights were then calculated as the arithmetic mean of the 6 largest "protrusion heights".

Dimensions and numerical values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise indicated, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm."

Every document cited herein, including any cross-referenced or related patent or application, is hereby incorporated by reference in its entirety unless expressly excluded or limited. The citation of any document is not an admission that it is relative to any prior art disclosed or claimed herein, either alone or in combination with any other reference or references , suggested or disclosed any such inventions. Furthermore, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document will control.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims (14)

1. An absorbent article for personal hygiene, said absorbent article comprising: a longitudinal axis, a transverse axis perpendicular to said longitudinal axis, a liquid-permeable topsheet, an acquisition layer, an absorbent core, a liquid-impermeable backsheet and an absorbent core, wherein said topsheet and said acquisition layer comprise fibers; wherein said absorbent core is located between said topsheet and said backsheet; wherein said absorbent core comprises absorbent material; wherein said absorbent material comprises at least 80% superabsorbent polymer, up to substantially 100% superabsorbent polymer, based on the total weight of said absorbent material; The absorbent article also includes an acquisition layer, wherein the acquisition layer has a width in a direction parallel to the transverse axis that is less than the width of the topsheet in a direction parallel to the transverse axis; and a topsheet/acquisition layer laminate comprising said liquid-permeable topsheet and said acquisition layer in face-to-face relationship, wherein the topsheet/acquisition layer laminate comprises three-dimensional protrusions extending from the plane of the topsheet/acquisition layer laminate, wherein the topsheet and the acquisition layer are nested together such that the protrusions formed on the Most of the three-dimensional protrusions in the topsheet coincide with and adhere to most of the three-dimensional protrusions formed in the acquisition layer. 2. The absorbent article of claim 1, wherein the topsheet and acquisition layer laminate are in intimate contact with each other. 3. The absorbent article according to any one of the preceding claims, wherein the absorbent core comprises a core wrap encapsulating the absorbent material, wherein the core wrap comprises a core wrap facing the topsheet/acquisition layer laminate and the bottom side facing the backsheet, and wherein the absorbent core includes one or more regions substantially free of absorbent material through which a portion of the top side of the core wrap is covered by one or A plurality of core wrap bonds are attached to a portion of the bottom side of the core wrap. 4. The absorbent article according to any one of the preceding claims, wherein the topsheet/acquisition layer laminate comprises one or more regions substantially free of three-dimensional protrusions. 5. The absorbent article according to claim 4, wherein said at least one or more regions of said topsheet/acquisition layer laminate that are substantially free of three-dimensional protrusions are distinct from said one or more regions of said absorbent core. The regions substantially free of absorbent material coincide. 6. The absorbent article according to any one of the preceding claims, wherein the absorbent article further comprises a distribution layer comprising a dry laid layer positioned between the topsheet/acquisition layer laminate and the backsheet. Laid fibrous structures and/or wet laid fibrous structures. 7. The absorbent article of claim 6, wherein a carrier layer is disposed between the topsheet/acquisition layer laminate and the drylaid fibrous structure. 8. The absorbent article of claim 6, wherein a carrier layer is disposed between the drylaid fibrous structure and the absorbent core. 9. The absorbent article according to any one of the preceding claims, wherein the fibers of the three-dimensional protrusions are substantially aligned with each other to form tunnel-shaped loops. 10. The absorbent article according to any one of claims 1-8, wherein the three-dimensional protrusions are formed from fibers of the topsheet and the acquisition layer, wherein the majority of the three-dimensional protrusions comprise opening-forming a base, an opposing distal portion, and one or more side walls between the base and the distal portion of the majority of three-dimensional protrusions, wherein the base, the distal portion, and the one or more Each sidewall is formed of fibers such that the majority of three-dimensional protrusions have openings only at the base. 11. The absorbent article according to any one of the preceding claims, wherein the length of the acquisition layer in a direction parallel to the longitudinal axis is less than or equal to the length of the topsheet in a direction parallel to the longitudinal axis . 12. Absorbent article according to any one of the preceding claims, wherein said topsheet/acquisition layer laminate is obtainable by a process comprising the steps of: (1) providing a first intermeshing roll and a second intermeshing roll having a nip therebetween, The first intermeshing roller includes a plurality of ridges and corresponding grooves extending substantially uninterrupted around the circumference of the first intermeshing roller, the second intermeshing roller includes a plurality of rows of circumferentially spaced teeth and a corresponding groove, wherein said plurality of rows of circumferentially spaced teeth extend in spaced relation around at least a portion of said second intermeshing roller; (2) intermeshing the topsheet and the acquisition layer together at the nip between the first intermeshing roll and the second intermeshing roll such that the first intermeshing roll The ridges of the intermeshing rollers extend into the grooves of the second intermeshing rollers, and the teeth of the second intermeshing rollers extend into the grooves of the first intermeshing rollers to form ridges including forming three-dimensional protrusions. The topsheet/acquisition layer laminate of the deformable portion. 13. The absorbent article according to any one of the preceding claims, wherein one of the topsheet or the acquisition layer of the topsheet/acquisition layer laminate is in the region of the three-dimensional protrusions of the topsheet/acquisition layer laminate Including one or more interruptions, so that the three-dimensional protrusions of the corresponding another non-interrupted top sheet or the acquisition layer are at least partially aligned with the three-dimensional protrusions of the interrupted top sheet or the acquisition layer of the interruption. fit together. 14. The absorbent article according to any one of the preceding claims, wherein the topsheet and the acquisition layer of the topsheet/acquisition layer laminate comprise a or a plurality of interruptions, and the three-dimensional protrusions of the top sheet overlap and fit together the three-dimensional protrusions of the acquisition layer, and wherein all the three-dimensional protrusions in the area of the top sheet/acquisition layer laminate The discontinuity in the topsheet does not coincide with the discontinuity in the acquisition layer in the region of the three-dimensional protrusions of the topsheet/acquisition layer laminate.