RU2813180C2 - Three-dimensional nonwoven materials and methods for their manufacture - Google Patents

Abstract

FIELD: nonwoven materials.

SUBSTANCE: three-dimensional nonwoven materials are disclosed. In one variant, the nonwoven fabric may comprise a plurality of fibres and may further comprise the first surface and the second surface opposite to each other, a perforated zone comprising a plurality of nodes extending from a reference plane on the first surface, a plurality of connecting bridges connecting the plurality of nodes to each other, and a plurality of holes providing a percentage open area for the perforated zone that is greater than about 15%, as determined by a test method based on analysis of a sample of the material. The material may further comprise the first and the second side zones, wherein the nonwoven fabric has a material width, and both the first and the second side zones have the width of the first and the second side zones, and wherein each of the widths of the first and second side zones is from about 5% to approximately 25% of the width of the nonwoven material.

EFFECT: three-dimensional nonwoven materials.

20 cl, 15 dwg, 2 tbl

Description

TECHNICAL FIELD

The present invention relates to nonwoven materials. More precisely, the present invention relates to three-dimensional nonwoven materials.

BACKGROUND OF THE INVENTION

Fibrous nonwoven fabric materials are widely used in numerous applications, including but not limited to absorbent structures and cleaning products, many of which are disposable. In particular, such materials are commonly used in absorbent personal care products such as diapers, diaper panties, potty training panties, feminine hygiene products, adult incontinence products, jockstraps and cleaning products such as baby wipes and adults. They are also commonly used in cleaning products such as wet and dry disposable wipes, which may be treated with cleaning or other formulations that are intended to be used manually or in combination with cleaning devices such as mops. Another use is in cosmetics such as cotton pads and wipes for cleansing and makeup removal.

In many of these applications, three-dimensionality and increased surface area are required properties. This is especially true regarding materials for the aforementioned personal care absorbent and cleaning products. For example, one of the primary functions of absorbent personal care products is to absorb and retain body waste such as blood, menstrual fluid, urine, and fecal matter. Some body secretions, such as solid and semi-liquid feces and menstrual fluids, do not penetrate such absorbent article components as easily as low-viscosity excretions such as urine and tend to spread over the surface of such materials. Distribution of body fluids throughout the nonwoven material may result in leakage of body fluids from the absorbent article in which the material is used. Semi-liquid stool, such as low-viscosity stool that may predominate in young children, and menstrual fluid may be particularly problematic to retain in an absorbent article. These secretions may move along the body-facing material of the absorbent article under the influence of gravity, movement, and pressure exerted by the wearer of the absorbent article. The movement of secretions is often directed towards the perimeter of the absorbent article, increasing the likelihood of leakage and smearing on the wearer's skin, which can make the skin difficult to clean and may result in an increased risk of irritation to the wearer's skin.

Although attempts have been made in the past to provide nonwoven materials designed to reduce the spread of secretions by creating a three-dimensional topography, there is still room for improvement. For example, various types of embossing were used to create three-dimensionality. However, this approach requires materials with a high basis weight to create a structure with significant relief, and the process can reduce the thickness of the material due to the compression and adhesion inherent in the embossing process. The compacted embossed sections can also create "welded spots" that keep body secretions out and can cause the material to become stiff and rough to the touch.

Other approaches to providing three-dimensionality to nonwoven materials may include forming fibers on a three-dimensional forming surface and creating perforations in the fibrous webs. Using modern technologies, including the formation of fibers, it is possible to obtain non-woven materials that have low elasticity at lower values of the base weight (based on the fact that soft fibers with the necessary aesthetic properties are used), and the relief is significantly disrupted when wound on the cylinder of a drawing device and passing through subsequent transformation processes. Creating perforations can strive to create three-dimensionality by displacing the fiber out of the plane of the original two-dimensional web. Typically, the degree of three-dimensionality is limited and, with sufficient force, the displaced fiber can be pressed back into its original position, resulting in at least partial closure of the perforation. Perforation processes that attempt to "set" displaced fibers outside the plane of the original web also tend to degrade the softness of the original web.

As a result, there is still a need for both a material and a process and device that provide three-dimensional characteristics that satisfy the above requirements. There still remains a need for a nonwoven material capable of sufficiently reducing the spread of body secretions in an absorbent article to help reduce the risk of leakage of excretions from the absorbent article. There still remains a need for a nonwoven material capable of minimizing the amount of body secretions coming into contact with the wearer's skin. There still remains a need for an absorbent article that can provide physical and emotional comfort to the wearer of the absorbent article.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment, the nonwoven fabric may comprise a plurality of fibers and may extend between a first end and a second end, wherein the nonwoven fabric has a material width and may further comprise a first surface and a second surface, wherein the first surface is on an opposite side to the second surface, perforated an area comprising a plurality of nodes extending from a reference plane on the first surface, a plurality of connecting bridges connecting the plurality of nodes to each other, wherein the majority of the plurality of nodes comprises at least three connecting bridges connected to adjacent nodes, and a plurality of openings providing for the perforated zone of the nonwoven fabric has a percentage open area that is greater than about 15%, as determined by a test method based on analysis of a sample of the material; a first side zone and a second side zone, wherein the first side zone has the width of the first side zone and the second side zone has the width of the second side zone, and wherein each of the width of the first side zone and the width of the second side zone can be from about 5% to about 25% of the width of the non-woven fabric.

In another embodiment, the nonwoven fabric may comprise a plurality of fibers and may extend between the first end and the second end, and may further comprise a perforated zone, wherein the perforated zone comprises a plurality of openings providing the perforated zone of the nonwoven fabric with a percentage open area that is more than approximately 15%, as determined by the test method based on analysis of a sample of the material; and a first side zone and a second side zone, wherein each of the first side zone and the second side zone has a percentage open area that is greater than about 0.5% and less than the percentage open area of the perforated zone, as determined by the test method based on sample analysis material, wherein the ratio equal to the sum of the tensile strength of the first side zone and the tensile strength of the second side zone divided by the tensile strength of the perforated zone can be from about 0.8 to about 2.5.

In yet another embodiment, the nonwoven fabric may comprise a plurality of fibers and may extend between the first end and the second end, and may further comprise a perforated zone, wherein the perforated zone comprises a plurality of openings providing the perforated zone of the nonwoven fabric with a percentage open area that is more than approximately 15%, as determined by the test method based on analysis of a sample of the material; and a first side zone and a second side zone, wherein each of the first side zone and the second side zone has a percentage open area that is greater than about 0.5% and less than the percentage open area of the perforated zone, as determined by the test method based on sample analysis material, wherein the Poisson's ratio of the perforated zone of the nonwoven material is less than about 3 at a strain of 1%, as determined by a test method for determining Poisson's ratio.

BRIEF DESCRIPTION OF GRAPHIC MATERIALS

A full and sufficient disclosure of the present invention, intended for one skilled in the art, is set forth more specifically in the remainder of the specification, in which reference is made to the accompanying drawings, in which:

in fig. 1 is a top view of an exemplary embodiment of a three-dimensional nonwoven fabric according to the present invention.

In fig. 2 is a scanning electron microscope (SEM) image providing a detailed view of the embodiment of FIG. 1.

In fig. 3 is an SEM image providing a cross-sectional view of the embodiment of FIG. 1, made along line 3-3.

In fig. 4 is a detailed view of the embodiment of FIG. 1 depicting transmitted light used to calculate the percentage open area of the perforated area of the nonwoven fabric of FIG. 1.

In fig. 5A and 5B are computed microtomography images showing cross-sections of two exemplary embodiments of a nonwoven fabric through a knot.

In fig. 5C is a CT microtomography image showing a cross-section of the GentleAbsorb® liner material of HUGGIES® Little Snugglers® diapers.

In fig. 5D is a bar graph showing the results of a test performed according to a test method for determining compression energy.

In fig. 5E is a bar graph showing the results of a test performed according to the test method for determining compression linearity.

In fig. 6A is a top view of an alternative embodiment of a three-dimensional nonwoven fabric.

In fig. 6B is a cross-sectional view of a portion of the material of FIG. 6A when viewed along line 6B-6B.

In fig. 6C shows a detail view of a portion of the material of FIG. 6A.

In fig. 6D shows an optical image of a fragment of the material of FIG. 6A.

In fig. 6E is a detail view of FIG. 6A depicting transmitted light used to calculate the percentage open area of one exemplary side zone of the nonwoven fabric of FIG. 6A.

In fig. 6F and 6G show plan views of alternative embodiments of a three-dimensional nonwoven fabric.

In fig. 7A is a schematic side view of an exemplary apparatus and process for producing a three-dimensional nonwoven fabric according to the present invention.

In fig. 7B is a schematic side view of an alternative exemplary apparatus and process for making a three-dimensional nonwoven fabric in accordance with the present invention.

In fig. 7C is a schematic side view of yet another alternative exemplary apparatus and process for making a three-dimensional nonwoven fabric in accordance with the present invention.

In fig. 7D is a cross-sectional view of the nonwoven fabric and carrier material taken along line 7D-7D of FIG. 7C.

In fig. 8A is a perspective view of a portion of a forming surface that may be used in the processes of FIGS. 7A-7C.

In fig. 8B is a detailed top view of a portion of an alternative forming surface that may be used in the processes of FIG. 7A-7C.

In fig. 9 is a side perspective view of one embodiment of an absorbent article containing a three-dimensional nonwoven material according to the present invention.

In fig. 10 is a plan view of the absorbent article of FIG. 9 with parts cut out for clarity.

In fig. 11A is a cross-sectional view of FIG. 10, made along line 11-11.

In fig. 11B is a cross-sectional view similar to FIG. 11A, but showing an alternative embodiment of the absorbent article.

In fig. 11C is a cross-sectional view similar to FIG. 11A and 11B, but showing yet another alternative embodiment of an absorbent article.

In fig. 12 is a plan view of one alternative embodiment of the absorbent article of FIG. 9.

In fig. 13 is a plan view of an exemplary nonwoven absorbent article of FIG. 12 with an exemplary bonding configuration depicted in relation to a nonwoven material.

In fig. 14 is a cross-sectional view of FIG. 12, taken along line 14F-14F.

In fig. 15 is a perspective view of exemplary equipment and apparatus for performing a test method based on analysis of a material sample as described herein.

Repeated use of reference numerals throughout the specification and drawings is intended to represent the same or similar features or elements of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

In one embodiment, the present invention generally relates to nonwoven fabrics 10, 110, 210, 310, methods 100', 100'', 100''' for making them, and absorbent articles 410, 510, 610, 710 containing such exemplary nonwoven materials . Each example is provided for illustrative purposes only and is not intended to be limiting. For example, features illustrated or described as part of one embodiment or figure may be used in relation to another embodiment or figure to produce yet another embodiment. The present invention is intended to include such modifications and variations. Any discussion below that refers to a specific illustrative nonwoven fabric 10, 110, 210, 310 is intended to apply to any other embodiments of nonwoven fabric 10, 110, 210, 310 described herein unless otherwise noted. It is further intended that any discussion below that refers to a particular nonwoven fabric making method 100', 100'', 100''' is intended to apply to any other embodiments of nonwoven fabric making methods 100', 100'', 100''' described in this document unless otherwise noted. In addition, any discussion below that refers to a specific absorbent article 410, 510, 610, 710 is intended to apply to any other embodiments of absorbent articles 410, 510, 610, 710 described herein unless otherwise stated. .

When presenting elements of the present invention or preferred embodiment(s) thereof, the use of singular or plural terms and when accompanied by the definition “specified” implies that there are one or more elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than those listed. Without departing from the spirit and scope of the present invention, many modifications and changes may be made thereto. Therefore, the exemplary embodiments described above should not be used to limit the scope of the present invention.

Definitions

The term "absorbent article" as used herein refers to an article that can be placed against or near the body (ie, in contact with the body) of the wearer to absorb and retain various liquid, solid, and semi-solid wastes excreted from the body. Absorbent products such as those described in this document should be discarded after a limited period of use and not washed or otherwise refurbished for reuse. It should be understood that the present disclosure applies to a variety of disposable absorbent articles, including, but not limited to, diapers, diaper panties, potty training panties, teenage panties, swim trunks, feminine hygiene products, including, but not limited to, pads or panties. menstrual products, incontinence products, medical garments, surgical pads and bandages, other personal care or health care garments, etc., without departing from the scope of the present invention.

The term "absorbent layer" as used herein refers to a layer capable of receiving and temporarily holding body fluids to slow and disperse the jet or flow of body fluids and subsequently releasing the body fluids therefrom into another layer or layers of the absorbent article.

The term “bonded” or “joined” as used herein refers to joining, gluing, joining, bonding or the like. two elements. Two elements will be considered connected or connected in relation to each other if they are combined, glued, connected, fastened, etc. with each other directly or indirectly, for example, if each of them is directly connected with intermediate elements. The binding or connection of one element to another can occur through continuous or intermittent connections.

The term “carded web” as used herein refers to a web containing staple length natural or synthetic fibers, typically having fiber lengths less than about 100 mm. Bundles of staple fibers may be opened to separate the fibers, which are then carded, in which the fibers are separated and combed to align them in the machine direction, after which the fibers are deposited onto a moving screen for further processing. Such webs are usually subjected to some kind of bonding process, such as heat sealing using heat and/or pressure. In addition or instead, the fibers can be subjected to bonding processes to bind the fibers together, for example through the use of a variety of powder adhesives. The carded web may be subjected to jet bonding, such as water jet bonding, to further interweave the fibers and thereby improve the integrity of the carded web. Carded webs, due to the alignment of the fibers in the machine direction, will generally have a machine direction strength greater than the cross direction strength after bonding.

The term “film” as used herein refers to thermoplastic film made using an extrusion and/or forming process, such as a cast film process or an extrusion blown film process. The term includes films with perforations, films with slots, and other porous films that constitute fluid transfer films, as well as films that do not transfer fluids, such as, but not limited to, barrier films, filled films, permeable films, and oriented films. .

The terms “jet bonding” and “jet bonding” as used herein generally refer to a spinning process for further increasing the degree of fiber bonding within a given fibrous nonwoven web or between fibrous nonwoven webs and other materials so as to cause separation of individual fibers and/or layers are more difficult as a result of bonding. Typically this is accomplished by securing the fibrous nonwoven web to some type of forming or support surface that has at least some degree of permeability to the pressurized fluid. A stream of pressurized fluid (typically multiple streams) is then directed onto a surface of the nonwoven web that is the reverse side to the supporting surface of the web. The pressurized fluid contacts the fibers and presses on portions of the fibers in the direction of fluid flow, thereby displacing all or a portion of the plurality of fibers toward the supporting surface of the web. As a result, additional bonding of the fibers occurs in a direction that can be called the Z-direction of the web (its thickness) in relation to a flatter area, its X-Y plane. If two or more individual webs or other layers are placed adjacent to each other on a forming/supporting surface and are exposed to a pressurized fluid, the typically desired result is that some of the fibers of at least one of the webs are forced into the adjacent web or layer thus causing fiber bonding in the area of interaction of the two surfaces such that the webs/layers result in bonding or mating with each other as a result of increased fiber bonding. The degree of binding or bonding will depend on a number of factors, including, but not limited to, the types of fibers used, their fiber lengths, the degree to which the web or webs are pre-bonded or bonded prior to the jet bonding process, the type of fluid used (liquids such as water, steam or gases, such as air), fluid pressure, number of fluid flows, process speeds, fluid exposure time, and porosity of the web or webs/other layers and forming/supporting surface. One of the most common jet bonding methods is called water jet bonding, which is a method well known to those skilled in the art of nonwoven fabrics. Examples of the jet bonding process can be found in U.S. Patent No. 4,939,016 to Radwanski et al., U.S. Patent No. 3,485,706 to Evans, and U.S. Patent No. 4,970,104 and U.S. Patent No. 4,959,531 to Radwanski, each of which is incorporated herein. document by reference in its entirety for all purposes.

The term "g/ ^m2 " refers herein to grams per square meter.

The term “hydrophilic” refers herein to fibers or fiber surfaces that are wetted by aqueous liquids upon contact with the fibers. The degree of wetting of materials can in turn be described in terms of contact angles and surface tension values of the liquids and materials in question. Equipment and techniques suitable for measuring the wettability of specific fibrous materials or mixtures of fibrous materials can be provided by the Cahn SFA-222 Surface Tension Force Analysis System or a substantially equivalent system. When measured with this system, fibers with contact angles less than 90 degrees are designated "wettable" or hydrophilic, and fibers with contact angles greater than 90 degrees are designated "non-wettable" or hydrophobic.

The term “liquid impermeable” as used herein refers to a layer or laminate in which body fluids, such as urine, will not pass through the layer or laminate under normal conditions of use in a direction generally perpendicular to the plane of the layer or laminate. at the point of contact with the liquid.

The term "liquid permeable" as used herein refers to any material that is not impermeable to liquid.

The term "meltblown" as used herein refers to fibers produced by extruding molten thermoplastic material through a plurality of small, usually circular, spinneret holes into threads or filaments from the melt into converging high-velocity streams of heated gas (e.g., air) that reduce the thickness of the filaments from molten thermoplastic material to reduce their diameter, which may be the diameter of a microfiber. Meltblown fibers are then carried by a high-velocity gas flow and deposited onto a collecting surface to form a web of randomly distributed meltblown fibers. Such a process is disclosed, for example, in US Pat. No. 3,849,241 to Butin et al., which is incorporated herein by reference. Meltblown fibers are microfibers that can be continuous or discontinuous, generally have a filament thickness of less than about 0.6 denier, and can be adhesive and self-bonding when deposited onto a collection surface.

The term "nonwoven fabric" refers herein to materials and webs of material that are formed without the use of a weaving or knitting process. Materials and webs of materials may have a structure of individual fibers, filaments or filaments (collectively referred to as "fibers"), which may be interlaminated, but not in a recognizable way, as in a knitted fabric. Nonwoven materials or webs can be formed using many methods, such as, but not limited to, meltblown methods, spunbond methods, carded fabric methods, etc.

The term "malleable" as used herein refers to materials that are deformable and that will readily conform to the overall shape and contours of the wearer's clothing.

The term "spunbond" as used herein refers to small diameter fibers that are produced by extruding molten thermoplastic material as filaments through a plurality of small holes in a rayon extruder die formed into a round or other shape, the diameter of the extruded filaments then being rapidly reduced a conventional method such as, for example, ejector pulling, and the methods described in US Pat. No. 4,340,563 to Appel et al., US Pat. No. 3,692,618 to Dorschner et al., US Pat. No. 3,802,817 to Matsuki et al. , US Patent Nos. 3,338,992 and 3,341,394 to Kinney, US Pat. No. 3,502,763 to Hartmann, US Pat. No. 3,502,538 to Peterson, and US Pat. No. 3,542,615 to Dobo et al., each of which is incorporated herein. document in its entirety by reference. Spunbond fibers are typically continuous and often have average denier values greater than about 0.3, and in one embodiment from about 0.6, 5, and 10 to about 15, 20, and 40. Spunbond fibers are generally non-tacky when deposited. onto the collecting surface.

The term “superabsorbent” as used herein refers to a water-swellable, water-insoluble organic or inorganic material capable of absorbing at least about 15 times its weight under the most favorable conditions and, in one embodiment, at least about 30 times its weight. of its weight, in an aqueous solution containing 0.9 weight percent sodium chloride. Superabsorbent materials can be natural, synthetic and modified natural polymers and materials. In addition, superabsorbent materials can be inorganic materials such as silica gels or organic compounds such as cross-linked polymers.

The term “thermoplastic” as used herein refers to a material that softens and can be shaped by heat and substantially returns to an unsoftened state when cooled.

The term “user” or “caregiver” as used herein refers to someone who puts on an absorbent article, such as, but not limited to, a diaper, diaper pant, potty training pant, teenage pant, incontinence product , or other absorbent article on the wearer of one of these absorbent articles. The user and wearer may be the same person.

Three-dimensional canvas with nodes, jumpers and holes

As shown in FIG. 1-3, the three-dimensional nonwoven fabric 10 may include a plurality of assemblies 12 and a plurality of tie bars 14 (only one of the assemblies 12 and one of the tie bars 14 are labeled in FIG. 1 for the sake of clarity). The assemblies 12 and connecting bridges 14 may be located within the perforated area 16 of the material 10. As best shown in the cross-sectional view of FIG. 3, the nodes 12 may extend from a base plane 18 on a first surface 20 of the nonwoven fabric 10. The base plane 18 may be defined as a generally flat area of the first surface 20 of the nonwoven fabric 10 that is distinct from the portion of the nonwoven fabric 10 forming the nodes 12. In other words, in the embodiment shown in FIG. 1-3, the base plane 18 may be formed by a first surface 20 of the nonwoven fabric 10 forming the connecting webs 14. The nonwoven fabric 10 may also include a second surface 22. The first surface 20 may be opposite to the second surface 22, as depicted in FIG. 3.

The assemblies 12 may have a variety of shapes and sizes, as will be described in more detail below when discussing the fabrication of the nonwoven fabric 10. In some embodiments, the assemblies 12 may have a generally cylindrical shape. In preferred embodiments, the assemblies 12 are configured to not contain any holes or perforations. In some embodiments, the assemblies 12 may have a height 15 (measured in a direction perpendicular to the reference plane 18) from about 1 mm to about 10 mm, and more preferably from about 3 mm to about 6 mm. The height 15 of nodes 12 is measured using the analytical techniques described in the node analysis test method described in the Test Methods section herein. In some embodiments, each of the majority of the nodes 12 may have an area (measured by the area of the node 12 within the reference plane 18) from about 5 mm ² to about 35 mm ² , and more preferably from about 10 mm ² to about 20 mm ² . A plurality of nodes 12 may be provided in the perforated area 16 such that the nodes 12 provide a node density of from about 1.0 knots/cm ² to about 3.0 knots/cm ² . The area of the nodes and the density of the nodes within the perforated zone 16 can be measured using the analytical techniques described in the material sample test method described in the Test Methods section herein.

As shown in FIG. 1 and shown in more detail in FIG. 2, connecting jumpers 14 can connect a plurality of nodes 12 to each other. A single jumper 14 may be described as extending only between two adjacent nodes 12. In other words, a single jumper 14 does not connect three or more nodes 12 to each other. In preferred embodiments, the majority of the plurality of nodes 12 may include at least three connecting jumpers 14 connected to adjacent nodes 12. In preferred embodiments, the majority of the plurality of nodes 12 may include ten or fewer connecting jumpers 14 connected to adjacent nodes 12. In some embodiments, the nonwoven fabric 10 may be configured such that the majority of the plurality of assemblies 12 may comprise from three to eight connecting straps 14 connected to adjacent assemblies 12. For example, in the embodiment depicted in FIG. 1 and 2, the majority of the plurality of nodes 12 comprises six connection jumpers 14 connected to adjacent nodes 12. In other embodiments, it may be preferable for the majority of the plurality of nodes 12 to include three to six connection jumpers 14 connected to adjacent nodes 12 , and in some embodiments will preferably comprise three to four connecting jumpers 14 connected to adjacent nodes 12.

The nonwoven fabric 10 may also include a plurality of holes 24 in the perforated area 16. The holes 24 may also be referred to as "perforations" herein. The holes 24 described herein are areas of the nonwoven fabric 10 that have a lower fiber density of the nonwoven fabric 10 compared to the assemblies 12 and connector strips 14. In some embodiments, the holes 24 may be substantially free of fibers. As used herein, the openings 24 are to be distinguished from the conventional interfiber spaces typically found in fibrous nonwovens. For example, in FIG. 2 is an SEM image depicting an exemplary nonwoven fabric 10 depicting a single opening 24 having a lower fiber density than adjacent nodes 12 and tie bars 14. Holes 24 may be formed between a plurality of tie bars 14 and a plurality of nodes 12 Individual openings 24 may be located between adjacent assemblies 12. Individual openings 24 may be formed between at least three connecting bridges 14 and at least three assemblies 12. In some embodiments, individual openings 24 may be formed between at least four connecting bridges. bridges 14 and at least four assemblies 12. In some embodiments, the majority of the plurality of holes 24 may be configured such that each has an area (measured by the area of the hole 24 within the reference plane 18) that ranges from about 5 mm ² to about 25 mm ² , more preferably from about 7 mm ² to about 20 mm ² , and even more preferably from about 7 mm ² to about 17 mm ² . The area of the holes 24 within the perforated area 16 can be measured using the analytical techniques specified in the material sample test method described in the Test Methods section herein.

In some embodiments, the plurality of openings 24 for the nonwoven fabric 10 may provide a percentage open area for the perforated area 16 of from about 10% to about 60%. In some preferred embodiments, the plurality of openings 24 for the nonwoven fabric 10 may provide a percentage open area for the perforated area 16 of from about 15% to about 45%. In some preferred embodiments, the nonwoven fabric 10 may provide a percentage open area for the perforated area 16 of about 20% to about 40%, or more preferably from about 20% to about 30%. As used herein, the percentage open area is determined using the test method based on the analysis of a material sample, which is described in the Test Methods section of this document. Although described in detail in the Test Methods section, the test method based on analysis of a material sample involves projecting a light source onto the nonwoven fabric 10 so that the holes 24 can be identified due to the fact that the holes 24 allow a greater percentage of light to pass through the nonwoven fabric 10. what is shown in Fig. 4 (with only three holes 24 marked for clarity), compared to assemblies 12 and jumpers 14.

The plurality of openings 24 may provide various advantageous properties to the nonwoven fabric 10. For example, the openings 24 may provide the nonwoven fabric 10 with improved fluid transfer and/or increased permeability. As an example, if the nonwoven fabric 10 is used in an article that absorbs and distributes fluid, the openings 24 may help provide increased absorption and distribution of fluids through and/or across the nonwoven fabric 10.

In particular, the plurality of holes 24 may improve the ability of a material, such as nonwoven fabric 10, to absorb and distribute BM material (also referred to herein as feces or excrement), resulting in less BM accumulation on the material 10 and, therefore, less BM in close proximity. to the skin of the wearer, an absorbent article containing such nonwoven material 10. To determine the ability of different nonwoven materials to effectively cope with simulated BM, a number of different nonwoven materials 10 (materials A-F), according to aspects of the present invention, were tested using test methods that determined the percentage the amount of accumulated BM. Such a test method as described in the "Determination of Fecal Simulant Residue" test method in US Pat. No. 9,480,609, entitled "Absorbent Article", which is incorporated herein by reference in its entirety to the extent not inconsistent with this document. Each of the different nonwoven fabrics tested were formed in a similar manner, but with different forming surfaces, resulting in different combinations of nodes 12, webs 14, and holes 24. These different combinations resulted in differences in the percentage open areas within the perforated zone 16, the average areas holes and volumetric properties of formed nonwovens. Various nonwoven materials, as well as their properties and test results are presented below in Table 1.

Material code Accumulated BM (%) Open area (%) Volume (mm) Average hole area (mm ² ) A 35.87 21.91 2,301 10.52 B 26.60 27.31 2,876 11.81 C 21.35 28.32 2.935 15.74 D 23.31 30.75 3,746 20.13 E 24.58 22.32 3,961 13.79 F 23.62 28.94 4.02 19.73 GentleAbsorb® 42.57 0 1.5 0

Table 1

First, it can be seen how effective materials containing holes 24 are in providing such materials with percentage open areas in the perforated zone 16 in reducing the amount of BM accumulation on such materials. For example, as shown in Table 1, Material A, which had the lowest percentage open area, still performed significantly better than GentleAbsorb® in terms of the amount of BM accumulated. In fact, all materials A-F tested performed well relative to GentleAbsorb®, generally maintaining a preferred percentage open area range of at least about 20%, or at least about 25%, or at least about 30 %, or from about 20% to about 30%.

It will also be seen that with such nonwoven fabrics 10 having the minimum percent open area values of the perforated zone 16 described herein, or the ranges of percent open area values described herein, it may be preferable for the nonwoven fabrics 10 to have apertures 24, having a relatively larger average area. For example, Table 1 shows that materials A and E have similar open area percentages. However, material E performed significantly better than material A for crowded BMs. As shown in Table 1, material E has an average hole area of 13.79 mm ² while material A has an average hole area of only 10.52 mm ² . Accordingly, it may be preferable that the nonwoven fabrics 10 of the present invention have average opening areas of at least 10.52 mm ² , or at least about 11 mm ² , or at least about 12 mm ² , or at least approximately 13 mm ² , or at least 13.79 mm ² . It may be preferable that the nonwoven fabrics of the present invention have such average aperture areas 24 while simultaneously having an open area percentage of the nonwoven fabric in the perforated zone 16 of at least 21.91%, or at least about 22%, or at least about 23%, or from about 20% to about 30%.

In some particularly preferred embodiments of the nonwoven materials of the present invention, it may be preferred that such materials have an open area percentage that is greater than about 27% or greater than about 27.31% and less than about 31%, or less than approximately 30.75%. For example, Materials B, C, and D demonstrate that Material C performed better than Materials B and C, with Materials B and D having percent open area values that are smaller and larger than Material C, respectively. Alternatively, it may be preferred that embodiments of the nonwoven fabrics of the present invention have average aperture areas 24 that are greater than about 11.81 mm ² or greater than about 12 mm ² and less than about 20.13 mm ² or less than approximately 21 mm ² . For example, Materials B, C, and D demonstrate that Material C performed better than Materials B and D, with Materials B and D having average hole area values of 24 that are smaller and larger than Material C, respectively. In other embodiments, it may be preferred that the nonwoven materials of the present invention have a percentage open area value that is greater than about 27% or greater than about 27.31% and less than about 31% or less than approximately 30.75%, and also had average opening areas that are greater than about 11.81 mm ² or greater than about 12 mm ² and less than about 20.13 mm ² or less than about 21 mm ² .

In fig. 5A-5C show examples of another advantageous property of the nonwoven fabric 10, which is related to the orientation of the fibers. In preferred embodiments of the nonwoven fabric 10, such as those shown in cross section in FIG. 5A and 5B, at least a majority of the plurality of assemblies 12 may be configured to have an anisotropy value greater than 1.0, as measured by the assembly analysis test method described in the Test Methods section herein. The units 12 have a higher level of fiber alignment in a direction 32 perpendicular to the reference plane 18 on the first surface of the nonwoven fabric 10. In FIG. 5C shows a comparative example of a nonwoven fabric currently used and marketed as GentleAbsorb® liner in HUGGIES® Little Snugglers® diapers manufactured and marketed by Kimberly-Clark Global Sales, LLC, as described in US Pat. No. 9,327,473. Anisotropy values for nonwoven materials in Fig. 5A-5C are shown below in Table 2. As shown in Table 2, the nonwoven fabrics 10 shown in FIGS. 5A and 5B included an anisotropy value greater than 1.0, or more specifically had anisotropy values of 1.07 and 1.25, respectively.

Sample Anisotropy value Standard deviation The nonwoven fabric shown in FIG. 5A 1.07 0.04 The nonwoven fabric shown in FIG. 5B 1.25 0.09 GentleAbsorb® liner (Figure 5C) 0.94 0.03

Table 2: Anisotropy values for the samples shown in FIG. 5A-5C

Without being limited by theory, it is believed that improved anisotropy values in the nodes 12 of the nonwoven fabric 10 described herein can be created by increasing the ratio of the depth of the forming slits 54 to the diameter of the forming slits 54, as will be described in more detail below.

In addition, it is believed that the increased anisotropy values of the nonwovens 10 of this disclosure provide improved compressive strength for the nonwovens 10 compared to other nonwovens, including GentleAbsorb® liner material. Due to its improved compression resistance, the nonwoven fabric 10 can maintain its elasticity throughout use and can be used in a variety of environments where it may be subject to compressive forces. For example, when used in an absorbent article, the nonwoven fabric 10 may be subjected to compressive forces from its original packaged state, where it is in a compressed package, until application to the wearer if the wearer is sitting or lying on the absorbent article. By providing improved compression resistance, the nonwoven fabric 10 can help maintain void volume for receiving, carrying, and/or storing wearer waste. Thus, the nonwoven fabric 10 may provide improved benefits to the wearer's skin by helping to prevent contact of body fluids with the wearer's skin, and provide potential product improvements by keeping body fluids away from the edges of the absorbent article, which may be a source of leakage.

As shown in FIG. 5D and 5E, the exemplary nonwoven fabric 110 described herein (depicted in FIG. 6A) was tested in two compression test methods in comparison to a comparative example of a nonwoven fabric currently used and marketed in as the GentleAbsorb® liner material in HUGGIES® Little Snugglers® diapers manufactured and marketed by Kimberly-Clark Global Sales, LLC, as described in U.S. Patent No. 9327473. A cross-sectional computed tomography image of a GentleAbsorb® liner sample is shown in FIG. 5C. In fig. 5D shows the results of the compression energy test and FIG. 5E shows the results of the compression linearity test. The results of these tests will be described below.

The compression energy test is more fully described in the Test Methods section of this document and consists of measuring the compressive strength of a material over three compression cycles by measuring the energy required to compress the nonwoven material from its original thickness at 5 gram-force to its final thickness at a force of approximately 1830 gram-force (approximately 10 kPa). As shown in FIG. 5D, the nonwoven fabric 110 of the present invention required more compressive energy in each compression cycle compared to the compressive energy required to compress the GentleAbsorb® liner control sample, and thus provides greater compressive strength. In fact, the compression energy test results demonstrate that the nonwoven fabric 110 provides benefits over the control sample. Specifically, nonwoven fabric 110 provided compressive energy greater than 40 gf*cm in cycle 1 and greater than 35 gf*cm in cycles 2 and 3. In fact, nonwoven fabric provided compressive energy greater than 50 gf*cm in cycles 2 and 3 and greater than 60 gf*cm in cycle 1.

Thus, it is preferred that the nonwoven materials of the present invention provide a compressive energy greater than 40 gf*cm, more preferably greater than 45 gf*cm, more preferably greater than 50 gf*cm, even more preferably greater than 55 gf*cm, and even more preferably greater than 60 gf* see cycle 1 of the compression energy test. It is preferable that the nonwoven materials of the present invention provide a compressive energy in the range of 40-65 gf*cm in cycle 1 of the compressive energy test. It is also preferable that the nonwoven materials of the present invention provide a compressive energy greater than 35 gf*cm, more preferably greater than 40 gf*cm, more preferably greater than 45 gf*cm, and even more preferably greater than 50 gf*cm in cycle 2 of the compression energy test. Thus, it is preferable that the nonwoven materials of the present invention provide a compressive energy in the range of 40-55 gf*cm in cycle 2 of the compressive energy test. It is also preferable that the nonwoven materials of the present invention provide a compressive energy greater than 35 gf*cm, more preferably greater than 40 gf*cm, more preferably greater than 45 gf*cm, and even more preferably greater than 50 gf*cm in cycle 3 of the compression energy test. It is preferable that the nonwoven materials of the present invention provide a compressive energy in the range of 40-55 gf*cm in cycle 3 of the compressive energy test.

By providing greater compressive strength, the nonwoven materials of the present invention may provide additional benefits. For example, when the nonwoven material 10 is used in the absorbent article 410, the nonwoven material 10 may retain void volume to interact with bodily waste by absorbing it into the absorbent assembly 444, which may help keep the user's skin drier and provide greater comfort. In particular, this advantage can be realized in embodiments in which the nonwoven material 10 is formed in the absorbent article 410 such that the nodes 12 extend from the reference plane 18 of the first surface 20 of the nonwoven material 10 to the absorbent element 434. Additionally, due to greater resistance to compression, the nonwoven fabric 10 can potentially provide greater lift and a softer feel to the skin of the wearer of such absorbent article 410.

In fig. 5E shows the results of the compression linearity test. The compression linearity test, as fully described in the Test Methods section of this document, is designed to measure the compression properties of a nonwoven fabric by compressing the material at a constant intensity between two pistons until it reaches a maximum preset force. The displacement of the upper piston, which compresses the material, is detected by a potentiometer. The amount of pressure required to compress the sample (P, gf/ ^cm2 ), depending on the thickness (displacement) of the material (T, mm), is displayed as a graph on the computer screen. The compression linearity value represents the degree of linearity of the compression curve. The greater the compression linearity value, the more resistant the material is to compression. As shown in FIG. 5E, nonwoven fabric 110 exhibited a compression linearity of approximately 0.75, while the GentleAbsorb® liner control exhibited a compression linearity of less than 0.50. Thus, in preferred embodiments, the nonwoven materials preferably have a compression linearity greater than 0.50, more preferably greater than 0.55, more preferably greater than 0.60, even more preferably greater than 0.65, and most preferably greater than 0.70. In some embodiments, the nonwoven material may have a compression linearity in the range of from about 0.50 to 1.0, or from about 0.50 to about 0.80.

In some embodiments, the nonwoven fabric 10 may include side zones and/or end zones that are different from the perforated zone 16. For example, as depicted in FIG. 1, the nonwoven fabric 10 may include a first side region 26a and a second side region 26b. The first and second side zones 26a and 26b may be generally parallel to each other and extend in the longitudinal direction 28. The first and second side zones 26a and 26b can be configured such that the first side zone 26a is located adjacent to the first side 16a of the perforated zone 16 and the second side area 26b is located adjacent to the second side 16b of the perforated area 16. In other words, the perforated area 16 may be located between the first side area 26a and the second side area 26b. In at least some embodiments, the side zones 26a, 26b may extend entirely from the leading edge 25 of the material 10 to the trailing edge 27 of the material 10. Additionally, in some embodiments, the perforated zone 16 may extend completely from the leading edge 25 of the material 10 to the trailing edge 27 material 10, such that the material 10 does not contain any end zones 26c, 26d. However, in other embodiments, the side zones 26a and/or 26b may only partially extend along the length of the nonwoven fabric 10. In such embodiments, the perforated zone 16 may extend entirely between the transverse side edges 47, 49 of the nonwoven fabric 10 along at least a portion of the length of the fabric 10 .

The nonwoven fabric 10 may have a width 35 defined between the transverse side edges 47, 49. The side areas 26a, 26b have widths 31a, 31b, respectively, while the perforated area 16 has a width 33. Although in FIG. 1 shows that the widths 31a, 31b are constant, in other embodiments they may vary. For example, the material 10 may be formed with a perforated area 16, the edges of which are curved and/or wavy in the longitudinal direction 28. In such embodiments, the widths 31a, 31b may increase and/or decrease in accordance with the shape of the perforated area 16. In the context of the present document widths 31a, 31b may refer to the largest width of the side zones 26a, 26b along the length of the material 10.

In general, it may be preferable that the side zones 26a, 26b have widths 31a, 31b that are not too large as a percentage of the overall width 35 of the material 10. For example, the side zones 26a, 26b may generally have greater tensile strength than the perforated zone 16 Accordingly, one advantage of the side zones 26a, 26b is that they help provide the material 10 with greater overall tensile strength and thus enable the material 10 to be processed by high speed manufacturing processes where the material 10 is processed in a stretched state (e.g., high speed manufacturing processes of absorbent products). However, if the widths 31a, 31b of the side regions 26a, 26b are too large, it has been found that the material 10 will curl undesirably when stretched, so that the material 10 may not be suitable for processing in desired high-speed manufacturing processes. For example, this curling may cause undesirable folding of the edges of the nonwovens as the materials move along the web path during the manufacturing process. It is believed that the difference in tensile strength between the side zones 26a, 26b and the perforated zone 16 is a key factor contributing to this curling.

In order to prevent curling of the material 10, or at least prevent a degree of curling that affects the processability of the material 10 in a high-speed manufacturing process, it has been found that it is desirable to maintain the widths 31a, 31b below certain percentages of the total width of the material 10. It is believed This characteristic helps ensure that the higher tensile strengths of the side zones 26a, 26b do not overwhelm the performance of the material 10 when subjected to tensile forces in high speed manufacturing processes. It has been found that material 10 and other materials of the present invention retain desired curl properties when subjected to tensile forces in conventional high speed manufacturing processes if each of the widths 31a, 31b is less than about 20% of the total width 35 of material 10. It may be more preferable if each of the widths 31a, 31b is less than about 25%, or less than about 20%, or less than about 17.5%, or less than about 15%, less than about 12.5% , or less than about 10% of the total width 35 of the material 10. In at least some of these embodiments, each of the widths 31a, 31b may be greater than about 5% of the total width 35 of the material 10. Therefore, the width 33 the perforated area may be from about 50% to about 90%, or from about 60% to about 90%, or from about 65% to about 90%, or from about 70% to about 90%, or from about 75% to about 90%, or from about 80% to about 90% of the total width 35 of material 10.

Each of the widths 31a, 31b may have similar dimensions. For example, the widths 31a, 31b may be such that one of the widths 31a, 31b is approximately 50% of the size of another of the widths 31a, 31b, or is approximately 25% of the size of another of the widths 31a, 31b.

In embodiments where the material 10 is used in an absorbent article, the side zones 26a, 26b may be used to engage the material 10 with the body of the absorbent article. In these embodiments, the widths 31a, 31b may be adjusted to provide sufficient area to bind the material 10 to the body of the article and to provide sufficient bond strength of the material 10 such that the material 10 does not delaminate during manufacture or use. Widths 31a, 31b that provide such advantages have been found to be from about 10 mm to about 40 mm, or from about 10 mm to about 35 mm, or from about 10 mm to about 30 mm, or from about 10 mm to about 25 mm, or from about 10 mm to about 20 mm.

It has also been discovered that in order to control curling of the material 10 under tension, such as the tensile forces to which the material 10 may be subjected in high speed manufacturing processes, there is a tensile strength ratio that is desirable to achieve between the zones 16, 26a, 26b. The tensile strength relationship is described in detail in the discussion of the tensile strength test method in the Test Methods section of this document. In general, the tensile strength ratio compares the added tensile strength of both side zones 26a, 26b with the tensile strength of the perforated zone 16. If the preferred tensile strength ratio is achieved, the dimensions of the side zones 26a, 26b need not be limited to a certain percentage of the total width 35 material 10 in order to achieve the desired curling properties. In general, it has been found that the more uniform the tensile strength of the material 10 is across its width 35, the less the material 10 curls when stretched. More specifically, it has been found that material 10 and other materials of the present invention can exhibit good curling performance if their tensile strength ratio is greater than about 0.8 and less than about 2.5. In other embodiments, it may be more preferable for the tensile strength ratio to be from about 0.8 to about 2, or from about 0.8 to about 1.75, or from about 0.8 to about 1.5. To determine the tensile strength of different zones 16, 26a, 26b, the material 10 was subjected to a tensile strength testing method. The tensile strength ratio of the material 10 can then be calculated according to equation (1) as specified in the tensile strength test method.

Although the side zones 26a, 26b help to provide increased overall tensile strength of the material 10, it has been found that the side zones 26a, 26b of the material 10 do not have a noticeable effect on the tapering property of the material 10. As used herein, the term "taper" is used to denote the tendency to reducing the width of the material when the material is subjected to increasing longitudinal tension. One material property used as a measure of contraction is the Poisson's ratio that the material has. It has been discovered that the material 10, or more specifically the perforated zone 16 of the material 10, may require a relatively low Poisson's ratio to be processed in a high speed manufacturing process, such as an absorbent article manufacturing process.

As one illustrative example, where the material 10 is used in an absorbent article, if the material 10 tapers too much when stretched, it may not cover the desired width of the absorbent article. Such extreme contraction may cause the material 10 to no longer cover the adhesive within the article. This exposed adhesive may undesirably bind other elements of the absorbent article to each other or make such articles difficult to open. It has been found that the advantageous Poisson's ratios of the perforated zone 16 of the material 10, limiting any contraction of the material 10, are ratios that are less than about 3 at 1% relative strain, or less than about 2.5 at 1% relative strain. , or less than about 2 at a relative strain of 1%, or less than about 1.5 at a relative strain of 1%. The Poisson's ratio of the perforated zone 16 can be determined according to the test method for determining the Poisson's ratio, which is described in the Test Methods section herein.

Another characteristic of the side zones 26a, 26b is that they may have open area percentages that are less than those of the perforated area 16. As described previously, it is desirable that the percentage open area of the perforated area 16 was high enough to provide the desired absorption properties of the material 10. In contrast, the side zones 26a, 26b should not have properties similar to those of the perforated zone 16 with respect to absorption or other fluid interaction properties. Accordingly, in some embodiments, the side zones 26a, 26b may have a percentage open area value that is less than the percentage open area value of the perforated zone 16. It may be preferable that the side zones 26a, 26b have a percentage open area value that is less than less than about 10%, or less than about 8%, or less than about 6%.

Also in some cases, the side areas 26a, 26b may have a minimum percentage of open area. For example, when the material 10 is a jet-bonded material, a forming process may be used to form micro-perforations 81 within the side regions 26a, 26b. The forming process may additionally or alternatively form regions of significantly reduced fiber density 39, wherein the process moves fibers from the first regions of the forming surface (e.g., portions of the outer surface 58 of the forming surface 50 between the perforations 71, as depicted in FIG. 8A) used to form material 10, to second regions of the forming surface (eg, perforations 71, as depicted in FIG. 8A). These micro-perforations 81 and areas of significantly reduced fiber density 39 can help achieve a certain percentage of open area in the side zones 26a, 26b. These characteristic features can be seen in Fig. 6E.

If the material 10 is a jet bonded material, it has been found that the percentage open area values of the side zones 26a, 26b can generally be greater than about 0.5%, or greater than about 0.6%, or greater. less than about 0.7% or more than about 0.8% or more than about 0.9% or more than about 1.0% or more than about 1.25% or more than approximately 2.5%, as determined by the test method based on analysis of a sample of the material. It has been found that the percentage open area values of the side zones 26a, 26b in the jet bonded nonwovens of the present invention, such as material 10, are typically greater than the percentage open area values of conventional nonwovens with similar basis weights, such as spunbond materials, meltblown materials and even spunlace materials that do not contain holes and/or projections or in which the holes and/or projections are not formed integrally when such materials are formed.

As described above, when the material 10 is a fluid-bonded material, the forming process may produce regions of reduced fiber density within the side zones 26a, 26b. Consequently, the forming process may also form regions of increased fiber density within the side zones 26a, 26b, for example, in regions corresponding to the perforations 71 in the forming surface 50. As the fibers move toward the perforations 71 in the forming surface 50, the perforations 71 are at least partially filled with fibers, thereby forming micropillars 13, as shown in FIG. 6B. This process of forming the micropillars 13 may be generally similar to the process of forming the nodes 12 of the perforated zone 16, although the resulting micropillars 13 may have a height 17 that is significantly less than the height 15 of the nodes 12. For example, the micropillars 13 may have a height 17 of approximately 0. 35 mm to about 1.0 mm, or from about 0.4 mm to about 0.9 mm, or from about 0.5 mm to about 0.9 mm, or from about 0.5 mm to about 0.8 mm .

Although not required, the nonwoven fabric 10 may further comprise a first end zone 26c and a second end zone 26d. The first end area 26c and the second end area 26d may be generally parallel to each other and extend in the transverse direction 30. The first end area 26c and the second end area 26d may be configured such that the first end area 26c is located adjacent the first end 16c of the perforated zones 16 and a second end zone 26d is located adjacent the second end 16d of the perforated zone 16. Any of such end zones 26c, 26d may be in some way similar to the side zones 26a, 26b as described above.

The holes 24 of the perforated zone 16 can have a variety of shapes and orientations. In the embodiment shown in FIG. 1-4, each hole 24 has a generally triangular shape. As best shown in FIG. 1 and 4, the triangular shape of the various holes 24 may have a variety of orientations. As will be described in more detail below, the holes 24 may have a variety of other shapes and orientations, which may be dictated by the process and equipment used to make the nonwoven fabric 10.

In some certain embodiments, the holes 24 may have a generally oval shape. For example, as shown in FIG. 6A, 6C and 6D, the holes 24 are elongated and have generally rounded sides. In at least some embodiments of the present invention, the openings 24 may have a major dimension 41 and a minor dimension 43, as depicted in FIG. 6D. The major dimension 41 may be the largest distance between two points on the material 110 surrounding the individual opening 24, while the minor dimension 43 may be the smallest distance between two points on the material 110 surrounding the individual opening 24 and which extends through the center of the opening 24. The center may be a geometric center. In some embodiments according to the present invention, it may be advantageous for the main dimension 41 to be oriented to extend substantially in the longitudinal direction 28. As used herein, the main dimension 41 is oriented to extend substantially in the longitudinal direction 28 when the main dimension 41 forms an angle 45 relative to the longitudinal direction 28 of less than forty-five degrees. In some specific embodiments, the major dimension 41 of most of the openings 24 may extend substantially in the longitudinal direction 28. In other embodiments, the major dimension 41 of all of the openings 24 may extend substantially in the longitudinal direction 28.

Such embodiments, where the major dimension 41 of the openings 24 of the material 110 and other materials of the present invention extend substantially in the longitudinal direction 28, may exhibit better absorption results than other embodiments when used in an absorbent article. As materials such as material 10 are exposed to a liquid and/or semi-liquid substance, the liquid and/or semi-liquid substance will tend to spread comparatively more in the longitudinal direction 28 than in the transverse direction 30. Accordingly, when the main dimension 41 of the holes 24 passes through being in the longitudinal direction 28, there is greater opportunity for liquid and/or semi-liquid material to be transferred through the openings 24 and into any liquid management and retention systems present in the absorbent article (eg, liquid discharge absorbent materials and/or absorbent elements). Some additional benefits may be that the fibers surrounding the holes 24 may be oriented slightly more in the longitudinal direction 28, which may improve the tensile strength of the material 10 - an important factor for the ability to process such materials in a high speed conversion process.

In more specific embodiments of the present invention, the major dimension 41 of the openings 24 may form an angle 45 with respect to the longitudinal direction 28 of less than about thirty-five degrees, or less than about twenty-five degrees, or less than about fifteen degrees. Of course, the major dimension 41 of not all of the holes 24 may be oriented at exactly the same angle 45 relative to the longitudinal direction 28. For example, even in embodiments where the major dimension 41 of most or most of the holes 24 extends substantially in the longitudinal direction 28, specific angles 45 formed by the main dimension 41 of the individual holes 24 may range from about zero degrees to about forty-five degrees.

In other embodiments, the major dimension 41 of the other openings 24 may extend substantially in the longitudinal direction 28, but the openings are oriented in opposite transverse directions. For example, as seen in FIG. 6A, 6C, and 6D, the major dimension 41 of the various depicted openings 24 is oriented such that it extends substantially in the longitudinal direction 28 but toward the first transverse direction. As can be seen, the other openings 24, the main dimension 41 of which extends substantially in the longitudinal direction 28, are oriented such that their main dimensions 41 extend towards a second transverse direction opposite to the first transverse direction.

Another characteristic feature of the material 110 and other materials provided by the present invention is that the aspect ratios of the holes 24 can be limited to a certain range. In at least some embodiments of the present invention, the average aperture aspect ratio of the materials of the present invention may be from about 1.3 to about 3.25, or from about 1.4 to about 3.0, or from about 1.3 to about 2.5, or from about 1.3 to about 2.0. These ranges of aspect ratios of the openings 24 may facilitate the absorption of interacting biological fluids, particularly in conjunction with the above-described orientations of the openings 24, improving the overall fluid handling properties of such materials.

In fig. 6C is an enlarged view of the region of material 110 containing trailing edge 27, showing in more detail the alignment and orientation of the assemblies 12, connecting bridges 14, and openings 24 of the material 110. Certain alignments and orientations of the members 12, 14, and 24 have been found to be capable of achieving desired material properties according to the present invention. For example, certain alignments and orientations can help provide desired tensile strength properties and/or desired tapering properties for machinability of materials, while still providing the material with a large open surface area and thus achieving advantageous properties related to handling fluids. Although such alignments and orientations are described in relation to a particular arrangement of material 110, it should be understood that other materials provided by the present invention may achieve such described alignments and orientations using other arrangements and materials.

The arrangement of nodes 12, connecting bridges 14 and holes 24 of material 110 forms a sequence of nodes 12 adjacent in the longitudinal direction and nodes 12 adjacent in the transverse direction. The nodes 12 are adjacent in the longitudinal direction, such as nodes 12a and 12b, if the line 85 drawn between the centers C1 and C2 does not pass through any holes 24 or other nodes 12 and forms an angle with respect to the longitudinal direction 28 of less than forty-five degrees . Likewise, nodes 12 are laterally adjacent, such as nodes 12c and 12d (or nodes 12d and 12e), if a line drawn between the centers of nodes 12c, 12d does not pass through any holes 24 or any other nodes 12 and defines the angle relative to the transverse direction is 30, which is less than forty-five degrees.

In some embodiments, it may be advantageous if the material 110 includes one or more tracks 21 of longitudinally adjacent nodes 12 that extend substantially in the longitudinal direction 28. Such tracks 21 extending substantially in the longitudinal direction 28 may help improve strength. to tear the material 110, thereby improving the ability of the material 110 to withstand the forces present in the high speed manufacturing process. The tracks 21 extending substantially in the longitudinal direction 28 may also help provide advantageous tapering properties to the material 110.

The track 21 consists of a sequence of connected nodes 12 adjacent in the longitudinal direction. The track 21 is said to extend substantially in the longitudinal direction 28 if lines drawn between the centers of nodes 12 adjacent in the longitudinal direction within the track 21, such as line 85 drawn between the centers C1, C2 of nodes 12a, 12b, form corners relative to the longitudinal dimension 28, being less than about twenty degrees, more preferably less than about fifteen degrees, even more preferably less than about ten degrees, and also even more preferably less than about five degrees. In fig. 6C, no angle is shown because the angle formed by the line 85 with respect to the longitudinal direction 28 is zero.

When each of the lines drawn between the centers of two or more nodes 12 and the center of the connected longitudinally adjacent support node 12 forms an angle with respect to the longitudinal direction 28 of less than approximately twenty degrees, the connected longitudinally adjacent node 12, which, as considered to be in the same track 21 as the support node 12, is a connected node 12 adjacent in the longitudinal direction for which a line drawn between its center and the center of the support node 12 forms a smaller angle. When lines drawn between the centers of the connected longitudinally adjacent nodes 12 and the center of the support node 12 form equal angles with respect to the longitudinal direction 28, the track 21 ends and none of the connected longitudinally adjacent nodes 12 are considered part of that particular tracks 21 with support unit 12.

In some embodiments, it may be preferable for the material 110 to have at least three tracks 21 extending substantially in the longitudinal direction 28, or at least four tracks 21 extending substantially in the longitudinal direction 28, or at least five tracks 21 extending substantially in the longitudinal direction 28, or at least six tracks 21 extending substantially in the longitudinal direction 28.

In other embodiments, it may be preferable for the material 110 to have a minimum number of tracks 21 extending substantially in the longitudinal direction 28, depending on the width 33 of the perforated zone 16 of the material 110. To assist in determining whether a material, such as material 110, has a minimum the desired number of tracks 21 extending substantially in the longitudinal direction 28, a dimensionless ratio of the number of tracks was developed. The value of this track ratio is equal to the width 33 of the perforated zone 16 of the material 110, expressed in millimeters, divided by the number of tracks 21 of the material 110 extending substantially in the longitudinal direction 28. Materials 110 having a track ratio value of less than approximately 15 may have sufficient tensile strength to be suitable for use in high speed manufacturing processes. In more preferred embodiments, the track ratio may be less than about 12, or less than about 10, or less than about 8. Although we do not intend to cover all contemplated suitable embodiments, the track ratio may generally be greater than about 3, or greater than about 4 , or more about 5.

The tracks 21 extending substantially in the longitudinal direction 28 have a length 23. The length 23 is the longitudinal length measured between the centers of the nodes 12 of the track 21 extending substantially in the longitudinal direction 28 that are closest to the rear edge 27 and the leading edge 25 of the material 10 within the track 21. In general, it may be advantageous for the track 21 extending substantially in the longitudinal direction 28 to extend a length 23 of more than about 25% of the total length L of the material 110, or more than about 50%, or more about 75%, or more than about 80%, or more than about 90% of the total length L of material 110. In at least some embodiments, a track 21 extending substantially in the longitudinal direction 28 may extend along the entire length L of material 110. Although It should be understood that not all of the tracks 21 extending substantially in the longitudinal direction 28 need to extend to such lengths 23. Instead, most of the tracks 21 extending substantially in the longitudinal direction 28 may extend to lengths 23 greater than the aforementioned values.

In general, the alignment of the nodes 12 in the above manner can be used to generally align the connecting jumpers 14 in the longitudinal direction 28. For example, lines 85 drawn between the centers of the longitudinally adjacent nodes 12 can approximately correspond to the locations and directions of the connecting jumpers 14 , connecting such nodes 12 adjacent in the longitudinal direction. By having such tracks 21 extending substantially in the longitudinal direction 28, at least some of the connecting webs 14 of the material 110 can be aligned substantially in the longitudinal direction. These substantially longitudinally aligned connecting bridges 14 may provide the material 110 with advantageous tensile strength and/or tapering properties as described above.

The material 110 may further comprise one or more tracks 37 of holes 24 extending substantially in the longitudinal direction 28. Like tracks 21 of the nodes 12, the track 37 of holes 24 consists of a sequence of holes 24 adjacent in the longitudinal direction. The holes 24 are adjacent in the longitudinal direction if a line drawn between the centers of adjacent holes 24 extends along a single connecting bridge 13 and forms an angle with respect to the longitudinal direction 28 of less than about forty-five degrees. The centers of the holes 24 may be the geometric centers of the holes 24.

The track 37 is considered to extend substantially in the longitudinal direction 28 if lines drawn between the centers of holes 24 adjacent in the longitudinal direction within the track 37, such as line 77 drawn between the centers of the holes 24a, 24b, form angles with respect to the longitudinal dimension 28 being less than about twenty degrees, more preferably less than about fifteen degrees, even more preferably less than about ten degrees, and also even more preferably less than about five degrees. In fig. 6C, no angle is shown because the angle formed by line 77 with respect to longitudinal direction 28 is zero degrees.

When each of the lines drawn between the centers of two or more holes 24 and the center of the longitudinally adjacent reference hole 24 forms an angle with respect to the longitudinal direction 28 of less than about twenty degrees, the longitudinally adjacent hole 24 is considered to be located in the same track 37 as the support hole 24, is a hole 24 adjacent in the longitudinal direction for which a line drawn between its center and the center of the support hole 24 forms a smaller angle. When lines drawn between the centers of the longitudinally adjacent holes 24 and the center of the reference hole 24 form equal angles with respect to the longitudinal direction 28, the track 37 ends and none of the longitudinally adjacent holes 24 are considered part of that particular track 37 with support hole 24.

As can be seen in FIG. 6C, the tracks 37 of the holes 24 adjacent in the longitudinal direction are offset laterally relative to the tracks 21 of the units 12 extending substantially in the longitudinal direction 28. That is, at least with respect to the tracks 21 of the units 12 extending substantially in the longitudinal direction 28 , and the tracks 37 of the holes 24, there are no holes 24 located in the longitudinal direction between the nodes 12 adjacent in the longitudinal direction, and this configuration provides a plurality of connecting bridges 14 that can extend substantially in the longitudinal direction 28 and provide the advantageous properties of the nonwoven fabric 110, associated with tensile strength and reduced contraction, which were mentioned above.

This may also be advantageous for material 110, where nodes 12 adjacent in the transverse direction maintain some degree of displacement in the longitudinal direction. For example, it may be advantageous if lines drawn between the centers of transversely adjacent nodes 12, such as nodes 12c and 12d or nodes 12d and 12e, form angles 19 with respect to transverse direction 30 that are greater than approximately zero degrees. It may be more preferable for the angle 19 to be more than about ten degrees, or more preferably more than about fifteen degrees, or more preferably more than about twenty degrees. In these embodiments, angle 19 may be less than about twenty-five degrees, or less than about twenty degrees, or less than about fifteen degrees. It is, of course, not necessary that all transversely adjacent nodes 12 in material 110 have the characteristic feature that a line drawn between the centers of transversely adjacent nodes 12 forms an angle of 19 within the described ranges. . In some embodiments, only a majority of the laterally adjacent nodes 12 may have this characteristic in that a line drawn between the centers of the laterally adjacent nodes 12 forms an angle 19 within the described ranges.

If the material 110 is a fluid bonded material, one unique property of the material 110 is the difference in the orientation of the fibers within the bond bridges 14 connecting longitudinally adjacent assemblies 12 and the bond bridges 14 connecting transversely adjacent assemblies 12. Anisotropy, one measure of the alignment of fibers within a single bond bridge 14, of bond bridges 14 connecting longitudinally adjacent assemblies 12, has been found to be generally greater than about 1.3, or greater than about 1.4, or greater than about 1. 5, according to the test method for determining the anisotropy of the jumpers. In contrast, the anisotropy of the connecting bridges 14 connecting nodes 12 adjacent in the transverse direction is generally less than about 1.1, or less than about 1.08, or less than about 1.05, according to the test method for determining the anisotropy of the bridges. These results indicate that the fibers within the tie bars 14 connecting longitudinally adjacent assemblies 12 are generally more aligned in one direction than the fibers within the tie bars 14 connecting transversely adjacent assemblies 12. This characteristic may further contribute to imparting tensile strength to the material 110 in the longitudinal direction 28.

The nonwoven fabric 10 may be composed of various fibers. In one embodiment, the nonwoven fabric 10 may contain synthetic fibers and binder fibers. In preferred embodiments involving synthetic fibers and binder fibers, the binder fibers may comprise at least about 5% of the plurality of fibers by total weight of the nonwoven fabric 10, and more preferably at least about 10% of the plurality of fibers by total weight of the nonwoven fabric 10. One Examples of synthetic fibers that may be used include polyester fibers, polypropylene fibers, and/or polypropylene-polyethylene bicomponent fibers, however, it should be understood that other fibers may be used without departing from the scope of the present invention. Exemplary binder fibers that may be used are ESC233 binder fibers available from FiberVisions, which have a linear density of 3 denier, 40 mm cut length, and 18 TPI, and ESC215 binder fibers available from FiberVisions, which have a linear density of 1.5 denier, a cut length of 40 mm and 18 threads per inch. However, it is possible to use other types of binder fibers.

In some embodiments, the nonwoven fabric 10 may additionally or alternatively contain natural fibers. The fibers of the nonwoven fabric 10 may be randomly arranged and may be staple length fibers such as those used in, for example, carded webs, airlaid webs, coform webs, etc., and they may have fiber lengths component less than 100 mm, and more often in the range of 10-60 mm. In addition or alternatively, the nonwoven fibers may include more continuous fibers, such as those used in, for example, meltblown or spunbond webs, and may have fiber lengths greater than 100 mm.

In some embodiments, the nonwoven fabric 10 may be configured as a single layer material. In other embodiments, the nonwoven fabric 10 may be configured as a laminate, wherein the laminate comprises a precursor material to which the nonwoven fabric 10 may be attached. An exemplary precursor material that will be described in more detail below in conjunction with FIG. 7, may be a spunbond material.

In fig. 6F and 6G show alternative embodiments of nonwoven fabrics 210 and 310, respectively. Alternative embodiments demonstrate that the nonwoven fabric 10, 110, 210, 310 may include assemblies 12, tie bars 14, and openings 24 in a variety of configurations. Each of the nonwovens 110, 210, 310 of FIG. 6A-6G respectively comprise a perforated zone 16 and side zones 26a, 26b, 26c, 26d. In the description of nonwovens 110, 210, 310 of FIG. 6A-6G, accordingly, it should be noted that for the purposes of clarity, not all of the assemblies 12, connecting bridges 14, and openings 24 are indicated.

In fig. 6F shows a nonwoven fabric 210 containing a perforated area 16 that contains a plurality of assemblies 12, each of which has four connecting webs 14 connected to adjacent assemblies 12. Some of the holes 24 in the nonwoven fabric 210 may be generally diamond shaped or have some curvature to take on the shape of a lens (a biconvex shape with two circular arcs connected at their end points), as shown in FIG. 6F. As shown in FIG. 6F, the holes 24 may be configured in the same orientation relative to each other.

Additionally, the embodiment of nonwoven fabric 210 shown in FIG. 6F may be less advantageous with respect to some aspects of material handling compared to the nonwoven fabric 110 shown in FIG. 6A-6D, due to the fact that the nonwoven fabric 210 does not contain tracks 21 of nodes 12 extending substantially in the longitudinal direction 28, since holes 24 are located between different nodes 12, preventing the combination of a sequence of nodes 12 into a track 21 of nodes 12 running along being in the longitudinal direction 28.

In fig. 6G shows yet another illustrative alternative nonwoven fabric 310 comprising a perforated zone 16 containing a plurality of assemblies 12. The nonwoven fabric 310 is configured such that some of the assemblies 12 (such as assembly 12a) have six connecting webs 14, while some nodes 12 (such as node 12b) have three connecting jumpers 14. As shown in FIG. 6G, different jumpers 14 may have different thicknesses. As also shown in FIG. 6G, some of the assemblies 12 may be configured to have a different area than the other assemblies 12. The perforated area 16 also includes a plurality of holes 24. The nonwoven fabric 310 is configured such that some of the holes 24 (such as hole 24a) are formed generally hexagonal in shape, while some of the holes 24 (such as hole 24b) are generally diamond shaped or have some curvature to take on a lens shape. As shown in FIG. 6G, the openings 24 may be configured such that some of the openings 24 have a different area than the other openings.

In fig. 7A depicts an illustrative process and apparatus 100' by which the nonwoven fabric 10 of the present invention can be manufactured. In fig. 7A shows a starting web 36 containing a plurality of fibers. The starting web 36 may be formed using various web forming techniques, such as, but not limited to, a wet layup process, foam layup, or carding. In a preferred embodiment, as shown in FIG. 7A, the starting web 36 may be formed in a wet layup process by depositing fiber and aqueous slurry 38 from the drum 40 onto the starting forming surface 42. The starting forming surface 42, as depicted in FIG. 7A may be a starting material such as spunbond fabric. However, it is contemplated that the fiber and aqueous slurry 38 may be applied directly to a belt, grid, or other surface forming the initial forming surface 42. The initial web 36 may be transferred by a belt 44 driven by a drive roller 46, or by other transfer devices known to one skilled in the art. If the starting web 36 is formed by a wet lay process, the starting web 36 can be dried using known techniques through the dryer 48.

The original web 36, whether produced on or off the production line, may be transferred to a forming surface 50. The forming surface 50 may be a surface of a texturing drum 52, such as a forming grid, with a portion of the exemplary forming surface 50 shown in more detail in FIG. 8A and 8B. The texturing drum 52 can be rotated as shown in FIG. 7A and can be driven by any suitable drive means (not shown), such as electric motors and gears, as is well known to those skilled in the art. The material forming the texturing drum 52 may be any number of suitable materials commonly used for such forming drums, including, without limitation, sheet metal, plastics and other polymeric materials, rubber, etc.

In fig. 8A depicts a first exemplary embodiment of a portion of the forming surface 50. The forming surface 50 may include a plurality of forming slots 54, a plurality of projections 56, and a plurality of bonding bridge forming regions 69. The connecting bridge forming regions 69 may be located between the plurality of forming slots 54 and the plurality of projections 56 and may generally be regions of the forming surface 50 that are neither the forming slot 54 nor the projection 56.

As will be described in more detail below, the geometric shape, spacing, and orientation of the forming slots 54, projections 56, and bond-forming regions 69 will correspond to the formation of the nodes 12, holes 24, and bond bridges 14 in the nonwoven fabric 10. In fact, the alignment and orientation of these forming The slots 54, projections 56, and bonding regions 69 may provide advantageous properties when forming nonwovens as described herein. For example, certain alignments and orientations can help provide desired tensile strength properties and/or desired tapering properties for machinability of materials, while still providing the material with a large open surface area and thus achieving advantageous properties related to handling fluids. Although such alignments and orientations are described in relation to the specific arrangement of forming surface 50 shown in FIG. 8A, and the forming surface 50' shown in FIG. 8B, it should be understood that other forming surfaces provided by the present invention can achieve the same described alignments and orientations using other arrangements.

As shown in FIG. 8A, the forming surface 50 may include a plurality of forming slits 54 corresponding to the shape and arrangement of the desired assemblies 12 of the nonwoven fabric 10. Although the forming slits 54 depicted in FIG. 8 are circular, it should be understood that any number of shapes and combinations of shapes may be used depending on the practical application. Examples of additional or alternative possible shapes of the forming slots 54 include, but are not limited to, ovals, crosshairs, squares, rectangles, diamond shapes, hexagons, and other polygons.

The forming slots 54 may be located in a plurality of tracks 55 (three tracks 55 are indicated in FIG. 8A) extending in the longitudinal direction 57 of the forming surface 50. The longitudinal direction 57 of the forming surface 50 may correspond to a circumferential direction, for example, if the forming surface 50 is part cylindrical texturing drum 52. The tracks 55 of the forming slots 54 may be formed from the forming slots 54 adjacent in the longitudinal direction. As described above with respect to the assemblies 12 of the nonwoven fabric 110 depicted in FIG. 6A and 6C, the forming slits 54 are adjacent in the longitudinal direction if a line 63 drawn between the centers of the forming slits 54 does not pass through any projections 56 or any other forming slits 54 and forms an angle with respect to the longitudinal direction 57 of less than forty-five degrees. Likewise, forming slits 54 may also be located in tracks extending in transverse direction 61 of forming surface 50 as long as a line drawn between the centers of forming slits 54 does not pass through any projections 56 or any other forming slits 54 and forms an angle with respect to the transverse direction 61 of the forming surface 50 being less than forty-five degrees.

When each of the lines drawn between the centers of two or more forming slots 54 and the center of the connected forming slot 54 adjacent in the longitudinal direction forms an angle with respect to the longitudinal direction 57 of the forming surface 50 that is less than about twenty degrees, the connected forming slot 54 adjacent in the longitudinal direction direction, which is considered to be in the same track 55 as the support forming slot 54, is a connected forming slot 54 adjacent in the longitudinal direction, for which a line drawn between its center and the center of the support forming slot 54 forms a smaller corner. When lines drawn between the centers of the connected forming slots 54 adjacent in the longitudinal direction and the center of the support forming slot 54 form equal angles with respect to the longitudinal direction 57 of the forming surface 57, the track 55 ends and none of the connected forming slots 54 adjacent in the longitudinal direction , is not considered part of this particular track 55 with the support forming slot 54.

The track 55 of the forming slits 54 consists of a sequence of connected forming slits 54 adjacent in the longitudinal direction. It may be preferable that one or more tracks 55 of the forming slots 54 be configured to extend substantially in the longitudinal direction 57. The track 55 is said to extend in the longitudinal direction when lines (such as line 63) drawn between the centers of the forming The slots 54 adjacent in the longitudinal direction form an angle with respect to the longitudinal direction 57 of less than about twenty degrees, more preferably less than about fifteen degrees, even more preferably less than about ten degrees, and also even more preferably less than about five degrees. In fig. 8A, no angle is shown because the angle formed by line 63 with respect to longitudinal direction 57 is zero degrees. In some preferred embodiments, the majority of the plurality of tracks 55 of the forming slots 54 located in the longitudinal direction 57 may be configured to extend substantially in the longitudinal direction 57. In some embodiments, such as the embodiment depicted in FIG. 8A, all the tracks 55 of the forming slots 54 on the forming surface 50 can be configured in this manner.

In some embodiments, it may be preferable for the forming surface 50 to have at least three tracks 55 of forming slots 54 extending substantially in the longitudinal direction 57 of the forming surface 50, or at least four tracks 55 extending substantially in the longitudinal direction 57. or at least five tracks 55 extending substantially in the longitudinal direction 57, or at least six tracks 55 extending substantially in the longitudinal direction 57.

The tracks 55 of the forming slots 54 extending substantially in the longitudinal direction 57 of the forming surface 50 may have a length extending across the entire forming surface 50, or may form only a portion of the length of the forming surface 50 in the longitudinal direction 57 (such as a portion of the circumference of the forming surface 50) . For example, in some embodiments, it is contemplated that one track 55 of forming slots 54 extending substantially in the longitudinal direction 57 of forming surface 50 may extend 5%, or 10%, or 15%, or 20%, or 25% or more of the length forming surface 50. In some embodiments, the track 55 of forming slots 54 extending substantially in the longitudinal direction 57 of the forming surface may extend less than 95%, or less than 90%, or less than 85%, or less than 80%, or less than 75% length of the forming surface 50. The forming surface 50 may also include a plurality of projections 56 extending from the outer surface 58 of the forming surface 50. As shown in FIG. 8, the projections 56 may have a pyramidal geometric shape, however, the projections 56 may have various other geometric shapes, cross-sectional shapes, spacing, and orientations. In some embodiments, the cross-sectional area of the plurality of protrusions 56 may decrease as they move away from the outer surface 58 of the forming surface 50. For example, the area of the pyramidal shaped protrusions 56 shown in FIG. 8, decreases as the protrusion 56 moves away from the outer surface 58 of the forming surface 50.

In general, the alignment of the forming slits 54 to form tracks 55 of the forming slits 54 extending substantially in the longitudinal direction 57 may align the bond bridge forming regions 69 in the longitudinal direction 57. For example, lines 63 drawn between the centers of the forming slits 54 adjacent in the longitudinal direction may approximately correspond to the locations and directions of the connecting bridge forming regions 69 that connect such forming slots 54 adjacent in the longitudinal direction. By having such tracks 55 of forming slots 54 extending substantially in the longitudinal direction 57, at least some of the connecting bridge forming regions 69 can be aligned substantially in the longitudinal direction. These substantially longitudinally aligned regions 69 forming the connecting bridges can result in a nonwoven fabric 110, such as described above, that can provide advantageous properties related to tensile strength and/or tapering, while at the same time maintaining sufficient the amount of open area as a percentage.

The projections 56 may be located in a plurality of tracks 59 (three tracks 59 are indicated in FIG. 8A) extending in the longitudinal direction 57 of the forming surface 50. The tracks 59 of the projections 56 may be formed from a series of projections 56 adjacent in the longitudinal direction. As described above with respect to the holes 24 in the nonwoven fabric 110 shown in FIG. 6A and 6C, the projections 56 are longitudinally adjacent if a line (such as line 65a or 65b in FIG. 8A) does not pass through any forming slots 54 or any other projections 56 and passes through a single bond bridge forming region 69 , and forms an angle with respect to the longitudinal direction 57 of the forming surface 50 of less than about forty-five degrees. The centers of the projections 56 may be the geometric centers of the projections 56. Likewise, the projections 56 may also be laterally adjacent as long as a line drawn between the centers of the projections 56 does not pass through any forming slots 54 or any other projections 56 and passes through a single the area 69 forming the connecting bridge and forms an angle with respect to the transverse direction 61 of the forming surface 50 of less than about forty-five degrees.

In some embodiments, a majority of the plurality of tracks 59 of protrusions 56 extending in the longitudinal direction 57 is offset laterally relative to the nearest adjacent track 55 of forming slots 54 extending substantially in the longitudinal direction 57. Due to this configuration as depicted in FIG. 8A (as well as in the alternative embodiments depicted in FIG. 8B), the bonding web forming regions 69 located between the forming slits 54 may extend substantially in the longitudinal direction 57. As a result, nonwoven fabrics 10 formed by such a forming surface 50 may include connecting webs 14 extending substantially in the longitudinal direction 28 of the nonwoven fabric 110, such as those described above in relation to the nonwoven fabric 110 in FIG. 6A and 6C. As noted above, this may provide the advantageous properties of improved tensile strength and reduced contraction of the nonwoven fabric 110 while maintaining a desired percentage open area of the perforated area 16 of the nonwoven fabric 110.

In some embodiments, the projections 56 in each track 59 may be configured such that the projections 56 adjacent in the longitudinal direction can form a line 65a or 65b forming an angle 67a, 67b, respectively, with the longitudinal direction 57. In some embodiments, this the angle 67a or 67b can be from 15 degrees to 60 degrees. As shown in FIG. 8A, longitudinally adjacent projections 56 in a track 59 of projections 56 may form a zigzag arrangement in the longitudinal direction 57 such that each projection 56 in one track 59 of projections 56 is offset in a transverse direction 61 relative to a previous projection 56 and a subsequent projection 56 in the track. 59 in the same transverse direction 61.

However, in some preferred embodiments, such as the embodiment shown in the detailed top view of the alternative forming surface 50' in FIG. 8B, the forming surface 50' may be configured to include one or more tracks 59 of projections 56 extending substantially in the longitudinal direction 57. The track 59 is said to extend in the longitudinal direction when lines (such as line 65) are drawn between the centers of the projections 56 adjacent in the longitudinal direction form an angle with respect to the longitudinal direction 57 of less than about twenty degrees, preferably less than about fifteen degrees, even more preferably less than about ten degrees, and also even more preferably less than about five degrees. In fig. 8B, no angle is shown because the angle formed by line 65 with respect to longitudinal direction 57 is zero degrees. In some embodiments, a majority of the plurality of protrusion tracks 59 56 extending in the longitudinal direction 57 are configured to extend substantially in the longitudinal direction 57. Also, in some embodiments, all or substantially all of the plurality of protrusion tracks 59 56 may be done this way.

As also shown in FIG. 8B, each protrusion 56 may have a length 73 and a width 75. The length 73 may also be referred to as the major dimension of the protrusion 56 and the width 75 may be referred to as the secondary dimension of the protrusion 56. As discussed above, comparing the length 73 to the width 75 of the protrusion 56 may result in an aspect ratio holes 24 in the nonwoven fabric 110, as described above in relation to FIGS. 6D. Preferably, the ratio of the length 73 to the width 75 of the protrusion 56 is greater than 1.0. In some embodiments, the ratio of length 73 to width 75 of protrusion 56 is from about 1.3 to about 3.25, or from about 1.4 to about 3.0, or from about 1.3 to about 2.5, or from approximately 1.3 to approximately 2.0. In some embodiments, the length 73 of the protrusion 56 may be oriented such that the length 75 extends substantially in the longitudinal direction 57 of the forming surface 50. As used herein, it is assumed that the protrusion 56, the length 73 of which is oriented in the longitudinal direction 57, includes projections 56 wherein the length direction 73 makes an angle of less than 45 degrees with the longitudinal direction 57 of the forming surface 50. In some embodiments, such as that shown in FIG. 8B, a plurality of projections 56 in the track 59 may be configured in this manner. In some embodiments, all or substantially all of the projections 56 in the track 59 of projections 56 may be configured in this manner. As also shown in FIG. 8B, adjacent tracks 59 of protrusions 56 may be configured such that the angular orientation of the major dimension (or length 73) of protrusions 56 extends in different lateral directions. For example, the leftmost track 59 of protrusions 56 includes protrusions 56 whose length 73 is oriented in a first transverse direction, while the second track 59 of protrusions 56 contains protrusions 56 whose length 73 is oriented in a second transverse direction opposite to the first transverse direction. In some embodiments, projections 56 in adjacent tracks 59 of projections 56 may be configured such that the lengths 73 of projections 56 extend in transverse directions that are mirror images of each other.

The forming surface 50 may also include one or more regions 60a, 60b substantially free of projections 56. The regions 60a, 60b, as will be described in more detail below, may correspond to the side regions 26a, 26b in the nonwoven fabric 10. In some embodiments, the regions 60a , 60b corresponding to the side areas 26a, 26b may include perforations 71. However, in preferred embodiments, if present, the perforations 71 in the areas 60a, 60b have a smaller cross-sectional area than the forming slots 54 in the forming surface 50 and may facilitate the removal of fluid environment during the jet bonding process. For example, the average area of the perforations 71 in the areas 60a, 60b may be less than the average area of the forming slots 54 in the forming surface 50. The perforations 71 in the areas 60a, 60b may result in the formation of micropillars 13, as depicted in FIG. 6B. The area of the outer surface 58 of the forming surface 50 between the perforations 71 in the areas 60a, 60b may form microperforations 81 and/or areas of lower fiber density 39.

As also shown in FIG. 7A, a typically perforated forming surface 50 is removably mounted on and above an optional porous inner drum shell 62 so that different forming surfaces 50 can be used for different end product designs. The porous inner drum liner 62 is coupled to a fluid removal system 64, which facilitates drawing the bonding fluid and fibers down into the forming slots 54 in the forming surface 50, thereby forming the nodes 12 in the nonwoven fabric 10. The porous inner drum liner 62 also acts as barrier to slow further movement of fibers into the fluid removal system 60 and other parts of the equipment, thereby reducing equipment clogging. The porous inner drum shell 62 rotates in the same direction and at the same speed as the texturing drum 52. Additionally, to further control the height of the nodes 12 on the nonwoven fabric 10, the distance between the inner drum shell 62 and the outer surface 58 of the forming surface 50 can be change. In general, the gap between the outer surface 58 of the forming surface 50 and the outer surface of the inner drum shell 64 will be in the range of from about 0 to about 5 mm. Other ranges may be used depending on the specific application and desired features of the nonwoven fabric 10.

The depth of the forming slots 54 in the texturing drum 52 or other projection forming surface 50 may range from 1 mm to 10 mm, but preferably from about 3 mm to 6 mm, to create the shaped assemblies 12 that are most suitable for the general applications contemplated. The cross-sectional diameter (or major diameter) of the forming slot 54 can be from about 2 mm to 10 mm, but preferably from 3 mm to 6 mm when measured along the major axis, and the spacing between the forming slots 54 based on the distance between centers can be from 3 mm to 10 mm, but preferably from 4 mm to 7 mm. The spacing between the forming slits 54 may be varied and selected depending on the particular application. Some examples of arrangements include, but are not limited to, aligned rows and/or columns, skewed arrangements, hexagonal arrangements, wavy arrangements, and arrangements featuring pictures, shapes, and objects.

The cross-sectional dimensions of the forming slits 54 and their depth influence the cross-section and height of the nodes 12 created in the nonwoven fabric 10. In general, the shapes of the forming slits 54 with sharp and narrow angles at the leading edge of the forming slits 54, when viewed in the processing direction, should avoided as they may sometimes impair the ability to safely remove the nonwoven fabric 10 from the forming surface 50 without damaging the assemblies 12. Additionally, the thickness/depth of the slot in the forming surface 50 will generally tend to match the depth or height of the assemblies 12 in the nonwoven fabric 10. However, Note that each of the depth, spacing, size, shape and other parameters of the slit can be changed independently of the other and can be changed based on the specific end use of the nonwoven fabric 10 being formed.

Without being limited by theory, it is believed that the particular ratios of the depth of the forming slits 54 to the diameter (or major dimension) of the forming slits 54 contribute to increasing the anisotropy of the nodes 12 in the nonwoven fabric 10. The term "major size" is used in the context if the forming slits 54 are not circular in shape. For example, if the forming slots 54 are elliptical in shape, the primary dimension will be the length of the ellipse along its major axis. It is believed that a ratio of the depth of the forming slot 54 to the diameter (or major dimension) of the forming slot 54 greater than 1.0 results in increased anisotropy of the nodes 12 of the nonwoven fabric 10. In some preferred embodiments, the ratio of the depth of the forming slots 54 to the diameter (or major dimension ) of the forming slots 54 can be from 1.0 to 1.2. As discussed above, increased anisotropy of the nodes 12 in the nonwoven fabric 10 may provide improved compression properties of the nonwoven fabric 10.

In the embodiment shown in FIG. 7A, the forming surface 50 is depicted in the form of a forming grid placed on the texturing drum 52. However, it should be understood that other means may be used to create the forming surface 50. For example, a perforated tape or mesh (not shown) that contains forming agents may be used. slits 54 formed in the tape or mesh at appropriate locations. Alternatively, flexible rubberized tapes (not shown) may be used that are impervious to the bonding flow of pressurized fluid except at the locations of the forming slots 54. Such tapes and meshes are well known to those of ordinary skill in the art, as are means for bringing about action and speed control of such belts and meshes. The texturizing drum 52 is more advantageous for forming the nonwoven fabric 10 of the present invention because it can be manufactured with an outer surface 58 between the forming slots 54 and the projections 56 that is smooth and impervious to the bonding fluid, and that does not leave a stranded wire pattern on the surface. non-woven material 10, which is what wire tapes tend to do.

In embodiments where the forming surface 50 forms part of the texturing drum 52 as a forming grid, the forming surface 50 and its characteristic features can be obtained using a variety of techniques. For example, the forming surface 50 and the features of its forming slots 54 and projections 56 may be formed by casting, molding, punching, stamping, machining, laser cutting, water jet cutting and 3D printing, or any other suitable technique.

The exemplary apparatus and method 100' may also include one or more fluid entangling devices 66. The most common fluid used in this regard is spunlace technology or water jet bonding technology, which uses pressurized water as the bonding fluid. Thus, the fluid entangling device 66 may include a plurality of high pressure fluid jets (not shown) to emit a plurality of pressurized fluid streams 68. These fluid streams 68, which is preferably water, may be directed toward the starting web 36 on the forming surface 50 and may result in further bonding of fibers within the nonwoven fabric 10 and/or the starting forming surface 42 (in the case where the starting forming surface is underlying web of material). The fluid flows 68 may also direct fibers in the source web 36 into the forming slits 54 and out of the reference plane 18 of the first surface 20 of the nonwoven fabric 10 and in the Z direction 38 perpendicular to the reference plane 18 to form nodes 12 in the nonwoven fabric 10 (see FIG. 2 and 3). Also, due to the fluid flows 68, at least a majority of the plurality of assemblies 12 can be configured to have an anisotropy value greater than 1.0, as described above. The fluid streams 68 may also direct the fibers in the source web 36 around the projections 56 on the forming surface 50 in the bond-forming region 69 to form a plurality of bond-straps 14 and a plurality of holes 24 on the nonwoven fabric 10.

In fig. 7A depicts a single fluid-entangling device 66, however, depending on the level of bonding required and the specific dimensions and qualities of the desired nonwoven fabric 10, a variety of such fluid-entangling devices 66 may be used. The bonding fluid streams 68 in the jet bonding devices 66 exit the nozzles through groups or jet lines (not shown) consisting of a row or rows of pressurized fluid nozzles with small holes typically ranging in diameter from 0.08 to 0.15 mm. and a gap of approximately 0.5 mm in the direction perpendicular to the processing direction. The nozzle pressure can range from about 5 bar to about 400 bar, but is typically less than 200 bar, except for heavy weight nonwovens 10 and if fibrillar structure formation is required. Other nozzle sizes, nozzle spacing, number of nozzles, and nozzle pressure may be used depending on the specific end application. Such jet bonding devices 66 are well known to those skilled in the art and are readily available from manufacturers such as Fleissner, Germany, and Andritz-Perfojet, France.

Jet bonding devices 66 will often have nozzle openings located or spaced from about 5 mm to about 20 mm, and more often from about 5 mm to about 10 mm, from the forming surface 50, although the actual spacing may vary depending on the base weight of the materials. that are affected, the fluid pressure, the number of individual nozzles used, the amount of vacuum used by the fluid removal system 64, and the speed at which the equipment operates.

In the embodiment shown in FIG. 7A, the jet bonding device 66 is a conventional water jet bonding device, the design and operation of which are well known to those skilled in the art, such as those described in US Pat. No. 3,485,706 to Evans, the contents of which are incorporated herein by reference throughout. its completeness for all purposes. Also see the description of hydraulic bonding equipment described by Honeycomb Systems, Inc., Biddeford, Maine, in the article entitled “Rotary Hydraulic Entanglement of Nonwovens,” reprinted from INSIGHT '86 INTERNATIONAL ADVANCED FORMING/BONDING Conference,” the contents of which are incorporated herein by reference in their entirety for all purposes.

The rotation speeds of the drive roller 46 and the texturing drum 52 can be set to different values relative to each other. In some embodiments, the rotation speed of the drive roller 46 and the texturing drum 52 may be the same. In other embodiments, the rotation speed of the drive roller 46 and the texturing drum 52 may be different. For example, in some embodiments, the speed of the texturing roll 52 may be less than the speed of the drive roll 46 to provide overfeed of the source web 36 on the forming surface 50 on the texturizing drum 52. Such overfeed can be used to provide various properties of the nonwoven fabric 10, such as improved formation 12 knots in non-woven material 10 and increased knot height 12.

After jet bonding has been effected by the bonding fluid streams 68 of the fluid bonding apparatus 66, the original web 36 becomes a jet bonded web forming the above-described nonwoven fabric 10 which includes a plurality of assemblies 12, a plurality of interconnecting webs 14 connecting the plurality of assemblies 12 to each other. , and a plurality of holes 24 as described above. The apparatus 100' and process may further include removing the jet-bonded nonwoven web 10 from the forming surface 50 and drying the jet-bonded web to form a three-dimensional nonwoven fabric 10. Drying the nonwoven fabric 10 can be accomplished using techniques known to one of ordinary skill in the art. In embodiments where the starting web contains binder fibers, drying the nonwoven fabric 10 may activate the binder fibers. Activation of the binder fibers may help maintain the three-dimensionality of the nonwoven fabric 10 by helping to maintain the geometric shape and height of the nodes 12 extending from the reference plane 18 on the first surface 20 of the nonwoven fabric 10 (as depicted in FIGS. 2 and 3).

In fig. 7B shows an alternative configuration of an apparatus and method 100'' for making nonwoven fabric 10 as described herein. As shown in FIG. 7B, apparatus and method 100'' may include a support web 43 that is brought into contact with a parent web 36 in advance of the fluid entangling unit 66. By separating the source web 36 from the support web 43, different feeding patterns of the source web 36 and the support web 43 can be achieved. For example, the source web 36 may be over-fed to the jet bonding unit 66 due to the size and speed of the drive roller 46 compared to the texturing drum 52. while the support web 43 may be fed into the jet bonding unit 66 at a speed corresponding to the speed of the texturing drum 52 by the drive roller 47. This is further described in US Pat. No. 9,474,660 to Kirby, Scott S.C. et al., which is included in this document in its entirety to the extent that it does not contradict this document.

As also shown in FIG. 7C, in some embodiments, the nonwoven fabric 10 may be combined with an additional web, such as a carrier material 151. The carrier material 151 may be attached to the nonwoven fabric 10 through any suitable joining mechanism, such as adhesive bonding or mechanical bonding. for example, binding by heat, ultrasound, pressure, or any other suitable binding mechanism. In some preferred embodiments, the carrier material 151 is bonded to the nonwoven fabric 10 in the first and second side zones 26a, 26b of the nonwoven fabric 10, but not in the perforated zone 16 of the nonwoven fabric. The carrier material 151 may be attached to the nonwoven fabric 10 after the fluid entangling unit 66 . In some embodiments, carrier material 151 may be attached to nonwoven fabric 10 after drying nonwoven fabric 10. In other embodiments, carrier material 151 may be attached to nonwoven fabric 10 before drying nonwoven fabric 10. Carrier material 151 may provide additional strength tensile strength of the nonwoven fabric 10 and may improve its processing under high speed converting and/or manufacturing conditions. The carrier material 151 is preferably a liquid permeable material and is bonded to the nonwoven fabric 10, for example, the carrier material 151 is bonded to the first surface 20 of the nonwoven fabric 10 containing the nodes 12, as well illustrated in FIG. 7D. It should also be noted that carrier material 151 may be added to the apparatus 100'' and process as illustrated and described in connection with FIG. 7B, wherein the support web 43 is supplied to the jet bonding unit 66 separately from the original web 36.

In fig. 7D is a cross-sectional view of the nonwoven fabric 10 and carrier material 151 viewed along line 7D-7D of FIG. 7C. As shown in FIG. 7D, the nonwoven fabric 10 bonded to the carrier material 151 may have a first surface 155 and a second surface 157. In the specific embodiment depicted in FIG. 7D, the material 10 is attached to the support sheet 151 in an orientation in which the nodes 12 of the material 10 extend from the reference plane 18 of the material 10, such as the first surface 20, to the second surface 157 of the support material 10. However, in other embodiments, other orientations of the material are contemplated. 10 and carrier material 151.

In some embodiments, the carrier material 151 may have a width that is greater than the width 35 of the material 10, as depicted in FIG. 7D. Such configurations may be desirable when a laminate consisting of material 10 and carrier material 151 is used as a liner material in an absorbent article. In such embodiments, the material 10 may be on top of the absorbent element of the article, while the carrier material 151 may extend completely between the edges of the body of the absorbent article. However, in other embodiments, the width of the carrier material 151 may be equal to the width of the material 10. Various configurations of the nonwoven material of the present invention, such as the material 10, and the auxiliary material, such as the carrier material 151, located in the absorbent article are described in more detail below. with reference to FIG. 11A-14.

The carrier material 151 may comprise any suitable nonwoven material, such as spunbond, meltblown, spunbond-meltblown-spunbond (SMS), spunlace, or the like. The carrier material 151 may generally have a basis weight of from about 30 ^gsm to about 100 ^gsm . Finally, the carrier material 151 may provide the material 10 with increased strength to allow the material 10 to be processed in high speed manufacturing processes. In at least some embodiments, the carrier material 151 may provide benefits directed to the properties of the material 10 associated with its interaction with fluids.

Carrier material 151 may be attached to material 10 at bonding regions 153. In at least some embodiments, the material 10 is attached to the carrier material 151 only in the bonding regions 153. As depicted, these bonding regions 153 may be located within the side zones 26a, 26b of the material 10. In some embodiments, the bonding regions 153 may have the same extent as the side zones 26a, 26b. However, in other embodiments, such as those depicted in FIGS. 7D, the binding regions 153 may be narrower than the side regions 26a, 26b. The material 10 and the carrier material 151 may be bonded using mechanical bonding methods such as heat bonding, ultrasonic bonding, pressure bonding, and the like. Alternatively, the material 10 and the carrier material 151 may be bonded using an adhesive.

However, in other embodiments, the material 10 may be further bonded to the carrier material 151 in bonding regions 153 as well as within the perforated area 16 of the material 10. For example, an adhesive may be applied to the carrier material 151 in areas that contact the perforated area 16 of material 10. In such embodiments, the nodes 12 of material 10 may be further associated with the support sheet 151 along with at least portions of the side regions 26a, 26b.

Although in FIG. 7A-7C show exemplary devices 100', 100'' and 100''' and jet bonding methods for making nonwoven fabric 10, it is contemplated that variations other than these devices 100', 100'' and 100''' may be used. and jet bonding processes. For example, as mentioned previously, the starting web 36 may be provided using various techniques other than a wet lay process, such as formed using a foam lay process or a carding process. Additionally, the source web 36 may be provided on a separate production line and wound onto roll spindles (not shown) and then transported to a separate production line to be introduced into the jet entangling process by the jet entangler 66 as described above.

Absorbent article

In one of many potential applications, the above-described nonwoven material 10 may be included in an absorbent article 410. FIG. 9-11 show a non-limiting illustration of an absorbent article 410, such as a diaper. Other embodiments of the absorbent article may include potty training briefs, teenage briefs, adult incontinence garments, and feminine hygiene products. Although the embodiments and illustrations described herein may generally be suitable for absorbent articles manufactured in the longitudinal direction of the product, which is hereinafter referred to as manufacturing in the processing direction of the product, it should be noted that one of ordinary skill in the art technicians will be able to apply the information provided herein to absorbent articles manufactured in the transverse direction of the product, which is hereinafter referred to as manufacturing in the transverse direction of the product, without departing from the spirit and scope of the present invention.

The nonwoven fabric 10 according to the present invention may form one or more components or one or more parts of components of the absorbent article 410 described below. In the exemplary embodiment described below and shown in FIG. 9-11, the nonwoven fabric 10 may form the body-facing liner 428 of the absorbent article 410. However, as stated above, it is contemplated that the nonwoven fabric 10 may additionally or alternatively form other components or other portions of components of the absorbent article 410, including, but not limited to, an outer cover 426, a fluid transfer layer 446, a fluid absorbent layer 448, a waist seal member 454, and/or a fastening system component such as a front fastener 492.

The absorbent article 410 shown in FIG. 9 may include a body 11. The absorbent article 410 may include a front waist region 412, a rear waist region 414, and a crotch region 416 located between the front waist region 412 and the rear waist region 414 and connecting the front and rear waist regions 412, 414, respectively. The front waist region 412 may be referred to as the front end region, the rear waist region 414 may be referred to as the rear end region, and the crotch region 416 may be referred to as the intermediate region.

As shown in FIG. 9 and 10, the absorbent article 410 may have a pair of longitudinal side edges 418, 420 and a pair of opposing waist edges, respectively designated a front waist edge 422 and a rear waist edge 424. The front waist region 412 may be adjacent to the front waist edge 422, and the rear the waist region 414 may be adjacent to the rear waist edge 424. The longitudinal side edges 418, 420 may extend from the front waist edge 422 to the rear waist edge 424. The longitudinal side edges 418, 420 may include portions curved between the front waist edge 422 and the rear waist edge 424 as shown in FIG. 10, while in other embodiments they may be configured to extend in a direction parallel to the longitudinal direction 430 along their entire length.

The front waist region 412 may include a portion of the absorbent article 410 that, when worn, is located at least partially on the front side of the wearer, while the rear waist region 414 may include a portion of the absorbent article 410 that, when worn, is located at least partially on the rear side wearing The crotch area 416 of the absorbent article 410 may include a portion of the absorbent article 410 that, when worn, is positioned between the wearer's legs and may partially cover the wearer's lower torso. The waist edges 422 and 424 of the absorbent article 410 are configured to surround the wearer's waist and together define a central waist opening 423 (as indicated in FIG. 9) for receiving the wearer's waist. Portions of the longitudinal side edges 418, 420 in the crotch region 416 may generally define openings for the wearer's legs when the absorbent article 410 is worn.

The absorbent article 410 may comprise an outer cover 426 and a body liner 428. The outer cover 426 and the body liner 428 may form a portion of the body 411. In one embodiment, the body liner 428 may be coupled to the outer cover 426 by layering by any suitable means, such as, but not limited to, adhesives, ultrasonic bonding, heat bonding, pressure bonding, or other conventional techniques. The outer cover 426 may have a length in the longitudinal direction 430 and a width in the lateral direction 432, which in the illustrated embodiment may be the same as the length and width of the absorbent article 410.

The body 411 may include an absorbent member 434. The absorbent member 434 may be positioned between the outer cover 426 and the body liner material 428. In one embodiment, the absorbent member 434 may have a length and width that are equal to or less than the length and width of the absorbent member. article 410. Body facing liner 428, outer cover 426, and absorbent member 434 may form part of absorbent assembly 444. Absorbent assembly 444 may also include a fluid transfer layer 446 (shown in FIGS. 10 and 11) and a fluid acquisition layer 448 (shown in FIGS. 10 and 11) between the body-facing liner 428 and the absorbent member 434. In some embodiments, if a fluid transfer layer 446 is present, then the absorbent layer 448 may be located between the body-facing liner 428 and the fluid transfer layer. medium layer 446, as is known in the art. The absorbent assembly 444 may also include a separating layer (not shown) located between the absorbent element 434 and the outer cover 426, as is known in the art. The absorbent assembly 444 may include other components in some embodiments. It is also contemplated that some embodiments may not include a fluid transfer layer 446 and/or an absorbent layer 448 and/or a separation layer.

The absorbent article 10 may be configured to retain and/or absorb liquid, solid, and semi-liquid bodily fluids emitted by the wearer. In some embodiments, a pair of sealed flaps (not shown) may be configured to provide a barrier against lateral spreading of body fluids. In some embodiments, the absorbent article 410 may further comprise leg elastics (not shown) known to those skilled in the art. In some embodiments, the absorbent article 10 may include a waist seal member 454. The waist seal member 454 may be located in the rear waist region 414 of the absorbent article 410. Although not shown, it is contemplated that the waist seal member 454 may additionally or alternatively be located in the front waist region 412 of the absorbent article 410.

Additional details regarding each of these elements of the absorbent article 10 described herein can be found below by referring to Figures 1-7.

External covering

The outer cover 426 and/or portions thereof may be breathable and/or liquid impermeable. The outer cover 426 and/or portions thereof may be elastic, stretchable, or nonstretchable. The outer cover 426 may be made of a single layer, multiple layers, laminates, spunbond textiles, films, meltblown textiles, elastic mesh, microporous webs, bonded carded webs, or foams made using elastomeric or polymeric materials. In one embodiment, for example, the outer cover 426 may be made of a microporous polymer film such as polyethylene or polypropylene.

In one embodiment, the outer cover 426 may be a single layer of liquid impervious material, such as a polymer film. In one embodiment, the outer cover 426 may preferably be stretchable and more preferably elastic in at least the lateral direction 432 of the absorbent article 410. In one embodiment, the outer cover 26 may be stretchable and more preferably elastic in both the lateral direction 432 and longitudinal 430 directions. In one embodiment, the outer cover 426 may be a multi-layer laminate in which at least one of the layers is liquid impermeable. In some embodiments, the outer cover 426 may be a two-layer structure, the two layers of which may be bonded to each other, for example, using a laminate adhesive. Suitable laminate adhesives may be applied continuously or intermittently as beads, sprays, parallel spirals, or the like, but it is understood that the inner layer may be bonded to the outer layer by other bonding methods, including but not limited to , by means of bonds obtained by ultrasonic welding, bonds obtained by heat welding, bonds formed under pressure, or the like.

The outer layer of the outer cover 426 may be of any suitable material and may be such that the wearer perceives an overall fabric-like texture or appearance. An example of such a material would be a 100% polypropylene diamond bonded carded web available from Sandler AG, Germany, such as Sawabond 4185®, 30 ^gsm or equivalent. Another example of a material suitable for use as the outer layer of the outer cover 426 may be a 20 ^gsm spunbond polypropylene nonwoven fabric. The outer layer can also be made from the same materials that can be made from the body facing liner 428 as described herein.

The liquid-impervious inner layer of the outer cover 426 (or the liquid-impermeable outer cover 426 if the outer cover 426 is of a single-layer construction) may be either vapor-permeable (i.e., "breathable") or vapor-impermeable. The liquid-impervious inner layer (or liquid-impervious outer cover 426 if the outer cover 426 is of a single-layer construction) may be made of a thin plastic film. The liquid-impermeable core layer (or the liquid-impervious outer cover 426 if the outer cover 426 has a single-layer structure) can prevent body fluids from leaking out of the absorbent article 410 and wetting items such as bed sheets and clothing, as well as the wearer and user. care.

In some embodiments in which the outer cover 426 has a single-layer structure, it can be embossed and/or matte finished to achieve a more fabric-like texture or appearance. The outer cover 426 may allow vapor to escape from the absorbent article 410 while preventing the passage of liquids. A suitable liquid impermeable, vapor permeable material may consist of a microporous polymer film or nonwoven material that has been coated or otherwise treated to impart the desired level of liquid impermeability.

Absorbent base

The absorbent body 434 may preferably be configured to be generally compressible, conformal, pliable, non-irritating to the wearer's skin, and capable of absorbing and retaining body fluids. The absorbent body 434 can be manufactured in a wide range of sizes and shapes (eg, rectangular, trapezoidal, T-shaped, I-shaped, hourglass, etc.) and from a wide range of materials. The size and absorbency of the absorbent body 434 must be compatible with the size of the intended wearer (infants to adults) and the volume of liquid received by the intended use of the absorbent article 410. The absorbent body 434 may have a length and width that may be less than or equal to the length and width absorbent article 410.

The absorbent element 434 contains absorbent material. In one embodiment, the absorbent element 434 may be composed of a web material of hydrophilic fibers, cellulosic fibers (eg, wood pulp fibers), natural fibers, synthetic fibers, sheets of woven or non-woven material, gauze-like mesh material or other stabilizing structures, superabsorbent material , binders, surfactants, selected hydrophobic and hydrophilic materials, pigments, lotions, odor control agents or the like, and combinations thereof. In one embodiment, the absorbent element 434 may be a matrix of cellulose fluff and superabsorbent material. In one embodiment, the absorbent element 434 may be made of a single layer of materials or, alternatively, may be made of two or more layers of materials.

Various types of wettable hydrophilic fibers can be used in the absorbent body 434. Examples of suitable fibers include natural fibers, cellulose fibers, synthetic fibers consisting of cellulose or cellulose derivatives, such as viscose fibers; inorganic fibers consisting of an inherently wettable material such as glass fibers; synthetic fibers derived from inherently wettable thermoplastic polymers, such as concrete polyester or polyamide fibers, or composed of non-wettable thermoplastic polymers, such as polyolefin fibers, which have been hydrophilized by suitable means. The fibers can be hydrophilized, for example, by treatment with a surfactant, treatment with silica gel, treatment with a material that has a suitable hydrophilic moiety and which cannot be easily removed from the fiber, or by coating the non-wettable hydrophobic fiber with a hydrophilic polymer coating during or after fiber formation. him. Suitable superabsorbent materials can be selected from natural, synthetic and modified natural polymers and materials. Superabsorbent materials can be inorganic materials, such as silica gels, or organic compounds, such as cross-linked polymers. In one embodiment, the absorbent element 434 may not contain superabsorbent material.

If a release layer is provided, the absorbent element 434 may be positioned on the release layer and placed on top of the outer cover 426. The release layer may be bonded to the outer cover 426, for example, with an adhesive. In some embodiments, the separating layer may be absent and the absorbent element 434 may be in direct contact with the outer cover 426 and may be directly associated with the outer cover 426. However, it should be understood that the absorbent element 434 may be in contact with, but not associated with, the outer cover 426. coating 426, and remain within the scope of the present invention. In one embodiment, the outer cover 426 may be comprised of a single layer, and the absorbent member 434 may be in contact with a single layer of the outer cover 426. In some embodiments, at least a portion of a layer, such as, but not limited to, a fluid transfer layer 446 and/or or separating layer, may be located between the absorbent element 434 and the outer cover 426. The absorbent element 434 may be associated with the fluid transfer layer 446 and/or the separating layer.

Body-facing cushioning material

The body-facing liner 428 of the absorbent article 410 may span the absorbent member 434 and the outer cover 426, and may be configured to accommodate the discharge of waste from a wearer, and may separate the wearer's skin from liquid waste retained by the absorbent member 434. The body-facing liner 434 428 may define at least a portion of the body-facing surface 419 of the base 411 configured to be adjacent to the wearer's skin.

In various embodiments, the fluid transfer layer 446 may be located between the body facing liner 428 and the absorbent member 434 (as shown in FIG. 11). In various embodiments, the absorbent layer 448 may be located between the body facing liner 428 and the absorbent member 434 or fluid transfer layer 446, if present (as shown in FIG. 11). In various embodiments, the body-facing liner 428 may be bonded to the absorbent layer 448, or fluid transfer layer 446 if no absorbent layer 448 is present, by adhesive and/or spot fusion bonding. Spot fusion bonding can be selected from ultrasonic bonding, temperature bonding, pressure bonding, and combinations thereof.

In one embodiment, the body facing liner 428 may extend beyond the absorbent member 434 and/or the fluid transfer layer 446, if present, and/or the absorbent layer 448, if present, and/or the separation layer, if present, with an overlap. portion of the outer cover 426 and may be bonded thereto in any manner deemed appropriate, such as by bonding thereto with an adhesive, substantially enclosing the absorbent member 434 between the outer cover 426 and the body liner material 428. In some embodiments, The body facing liner 428 and the outer cover 426 may have the same width and length dimensions. In some embodiments, however, the body facing liner 428 may be narrower than the outer cover 426 and/or shorter than the outer cover 426. In some embodiments, the length of the body facing liner 428 may be in the range of 50 -100% of the length of the absorbent article 410, measured in a direction parallel to the longitudinal direction 430. In some embodiments, the body facing liner 428 may be wider than the outer cover 426. It is also contemplated that the body facing liner 428 may not extend beyond limits of the absorbent element 434 and/or may not be attached to the outer cover 426. In some embodiments, the body facing liner 428 may surround at least a portion of the absorbent element 434, including surrounding both longitudinal edges of the absorbent element 434 and/or one or more end edges of the absorbent element 434. It is further contemplated that the body facing liner 428 may be comprised of more than one segment of material.

The body facing liner 428 can have a variety of shapes, including a rectangular shape, an hourglass shape, or any other shape. The body facing liner 428 may be suitably deformable, soft to the touch and non-irritating to the wearer's skin, and may be as or less hydrophilic than the absorbent member 434, allowing body waste to easily penetrate the absorbent member 434 and providing the wearer with a relatively dry surface.

The body-facing liner 428 can be made from a wide variety of materials, such as synthetic fibers (e.g., polyester or polypropylene fibers), natural fibers (e.g., wood or cotton fibers), a combination of natural and synthetic fibers, porous foams, mesh foams, perforated plastic films or the like. Examples of suitable materials include, but are not limited to, cellulose manmade fibers, wood, cotton, polyester, polypropylene, polyethylene, nylon or other heat-bonded fibers, polyolefins such as, but not limited to, polypropylene-polyethylene copolymers, linear low density polyethylene and aliphatic esters such as polylactic acid, perforated film webs, mesh materials, etc., and combinations thereof.

A variety of woven and nonwoven materials can be used for the body-facing liner 428. The body-facing liner 428 may include a woven material, a non-woven material, a polymer film, a film-fabric laminate, and the like, as well as combinations thereof. Examples of the nonwoven fabric may include spunbond textile, meltblown textile, coform fabric, carded fabric, bonded carded fabric, two-component spunbond textile, spunlaced fabric, or the like, as well as combinations thereof. The body-facing liner 428 need not be a single layered structure and thus may comprise more than one layer of fabrics, films and/or webs, as well as combinations thereof. For example, the body-facing liner 428 may include a support layer and a projection layer that have been water-jet bonded. The projection layer may include hollow projections, such as those disclosed in US Pat. No. 9,474,660 to Kirby, Scott S.C. et al., and as described in FIG. 8.

For example, the body-facing liner 428 may consist of a meltblown or spunbond web composed of polyolefin fibers. Alternatively, the body-facing liner 428 may be a knitted carded web consisting of natural and/or synthetic fibers. The body-facing liner material 428 may be comprised of a substantially hydrophobic material, and the hydrophobic material may optionally be treated with a surfactant or otherwise treated to impart a desired level of wettability and hydrophilicity. The surfactant may be applied by any conventional method such as spraying, printing, brushing or the like. The surfactant may be applied to the entire bodyside liner 428, or it may be selectively applied to specific areas of the bodyside liner 428.

In one embodiment, the body facing liner 428 may be made of a bicomponent nonwoven fabric. The non-woven two-component fabric can be a two-component spunbond fabric or a bonded carded two-component fabric. An example of a bicomponent staple fiber includes polyethylene/polypropylene bicomponent fiber. In this particular bicomponent fiber, polypropylene forms the core and polyethylene forms the fiber sheath. Without departing from the scope of the present invention, it is possible to use fibers oriented differently, for example, in the form of multiple lobes, side by side, end-to-end. In one embodiment, the body facing liner 428 may be a spunbond backing having a basis weight of from about 10 or 12 to about 15 or 20 ^gsm . In one embodiment, the body facing liner 428 may be a 12 gsm ^spunbond -meltblown-spunbond backing having 10% meltblown content applied between two layers of spunbond.

Although the outer cover 426 and the body-facing liner 428 may comprise elastomeric materials, it is contemplated that the outer cover 426 and the body-facing liner 428 may be composed of materials that are not generally elastomeric. In one embodiment, the body-facing liner 428 may be stretchable, and more preferably elastic. In one embodiment, the body-facing liner 428 may be suitably stretchable and more preferably elastic in at least the transverse or peripheral direction of the absorbent article 410. In other aspects, the body-facing liner 428 may be suitably stretchable and more preferably elastic as in the transverse and longitudinal directions 432, 430, respectively.

In the exemplary embodiment depicted in FIG. 9-11B, the above-described water-jet bonded nonwoven fabric 10 may be used as the body facing liner material 428. As shown in FIG. 11A, the nonwoven fabric 10 of the present invention may be oriented such that a plurality of nodes 12 extend from a reference plane 18 on the first surface 20 to the absorbent member 434. That is, the second surface 22 of the nonwoven fabric 10 may define at least a portion of the body-facing surface 419 of the base 411, configured to be located against the skin of the wearer. The perforated zone 16 of the nonwoven fabric 10 may be configured to allow secretions to flow through a plurality of openings 24 in the nonwoven fabric 10 into underlying structures of the absorbent assembly 444, such as the fluid acquisition layer 448, the fluid transfer layer 446, and the absorbent member 434.

By having the nonwoven fabric 10 configured so that the nodes 12 extend toward the absorbent body 434, the nodes 12 can help create additional void volume to accommodate waste while it is absorbed by and carried through the absorbent body 444 while still remaining out of the way. from the body-facing surface 419 of the body 411 of the absorbent article 410. In this orientation, the nonwoven fabric 10 can create a volume of voids for discharge between the nonwoven fabric 10 and any underlying structures in the absorbent article 10 due to the fact that the nodes 12 of the nonwoven fabric 10 create a gap between the base plane 18 of first surface 20 and any such underlying structure. The volume of secretion voids created by the nonwoven fabric 10 may vary depending on the height of the nodes 12, the density of the nodes 12, and the area of the perforated zone 16 of the nonwoven fabric 10, and can be designed to be proportionally suitable for different step sizes of absorbent articles 410 and absorbents. 410 products designed to handle different discharges. By creating a void volume with these properties, the nonwoven fabric 10 can absorb secretions with minimal spread of the secretions across the body-facing surface 419 of the body 411 of the absorbent article 410. By doing so, the nonwoven fabric 10 can help reduce the area of contact of secretions with the wearer's skin and reduce the potential irritation to the wearer's skin.

In fig. 11A depicts a nonwoven fabric 10 forming a body-facing liner 428 for an absorbent article 410. In such a configuration, the nonwoven fabric 10 may have a width substantially equal to the width of the outer cover 426. A second surface 22 of the nonwoven fabric 10 may define a body-facing absorbent surface 419 article 410 and may be configured to contact the wearer's skin.

In fig. 11B illustrates an alternative embodiment of an absorbent article 510 similar to the absorbent article 410 described in FIG. 11A unless otherwise noted herein. In fig. 11B, the absorbent article 510 may include a nonwoven material 10 bonded to a carrier material 151 to form a body-facing liner material 528. The carrier material 151 may be combined with the nonwoven fabric 10, for example, in the method 100'' described above with respect to fig. 7C. The carrier material 151 may be coupled to the first side 20 of the nonwoven fabric 10. The carrier material 151 may be positioned between the nonwoven fabric and the absorbent member 434. In the embodiment shown in FIG. 11B, carrier material 151 may be positioned between the nonwoven fabric 10 and the fluid absorbent material 448.

Other orientations and variations of the nonwoven material 10 in an absorbent article also fall within the scope of the present invention. For example, although the nonwoven fabric 10 is shown in FIG. 11A and 11B in an orientation in which the nodes 12 extend from the reference plane 18 of the first surface 20 to the absorbent element 434, it is also contemplated that the nonwoven fabric 10 may be oriented such that the nodes 12 extend from the reference plane 18 of the first surface 20 away from the absorbent element 434, as shown in FIG. 11C. In the embodiment of the absorbent article 610 shown in FIG. 11C, the nonwoven fabric 10 may form a body facing liner 628, wherein the first surface 20 provides a body facing surface 419 configured to be against the skin of a wearer. In such an embodiment, the nodes 12 may provide separation from body fluids that may be present on the reference plane 18 of the first surface 20 of the nonwoven fabric 10. Additionally, the nodes 12 may provide barriers to the spread of body fluids, such as BM, on the first surface 20 of the nonwoven fabric 10 By reducing the spread of secretions on the nonwoven material 10, the nonwoven material 10 can help reduce irritation to the wearer's skin and the likelihood of secretions leaking out of the absorbent article 610.

In fig. 12 depicts an absorbent article 710 similar to absorbent articles 410, 510 and 610. In the embodiment shown in FIG. 12, article 710 may comprise a nonwoven fabric of the present invention, such as fabric 10. As can be seen more clearly in FIG. 14, which is a cross-sectional view of article 710 viewed along line 14F-14F shown in FIG. 12, the nonwoven fabric 10 may be positioned over the body facing liner 728. In some exemplary embodiments, the body facing liner 728 may be a material such as the carrier material 151 described in relation to the method 100''' shown in fig. 7C.

In the embodiment shown in FIG. 12, the material 10 may have a width (width 35 described in FIG. 1) that is generally less than the width of the body facing liner material 728. In such embodiments, the material 10 may be positioned on the base 719 of the article 710 so that it is positioned at generally above the absorbent element 434. In some embodiments, the perforated zone 16 of the material 10 may completely cover the absorbent element 434. In such embodiments, the side zones 26a, 26b may be located entirely outside the absorbent element 434. However, in other embodiments, the side zones 26a, 26b 26b may at least partially overlap with the absorbent element 434.

The material 10 may be bonded to the substrate 719 through at least the entire front waist bonding region 173 and the entire rear waist bonding region 171. The front waist binding region 173 may generally be located proximate the leading edge 25 of the material 10. The front waist binding region 173 also extends throughout the entire perforated area 16 of the material 10 and in some embodiments, as shown, for example, in FIG. 12 may at least partially extend through the side areas 26 and/or 26b. The front waist binding region 173 may have a length 186 that is about 20% longer than the overall length of material 10, or about 30% longer, or about 35% longer, or about 40% longer, or about 45% longer, or about 50% more than the overall length of the material 10. In some preferred embodiments, the length 186 may be about 60% less, or about 55% less, or about 50% less than the overall length of the material 10. In at least some embodiments, the front waistband the binding region 173 may generally be formed by mechanical binding means, such as binding by heat, ultrasound, pressure or the like. However, in other embodiments, the front waist binding region 173 may be formed by binding with adhesive.

A large area covered by the front waist bonding region 173 may be particularly advantageous when the average areas of the holes 24 of the material 10 in the perforated area 16 are greater than about 17 mm ² , or more preferably when these average areas are greater than about 20 mm ² . With such large average areas of the openings 24 of the article 710 containing said material 10, the risk of penile compression for male wearers increases. By binding a large portion of the anterior region of the material 10 to the base 719, the openings 24 in the anterior portion of the article 710 are prevented from encircling the male wearer's penis.

A rear waist bonding area 171 is located proximate the rear edge 27 of the material 10 and ties the material 10 to the backing 719. Like the front waist bonding region 173, the rear waist bonding region 171 may extend through the entire perforated area 16 of the material 10 and also, in some embodiments, may at least partially extend through the side zones 26 and/or 26b. The rear waist bonding region 171 may be generally formed by mechanical bonding means, such as bonding by heat, ultrasound, pressure, or the like. However, in other embodiments, the back waist binding region 171 may be formed by binding with adhesive.

The rear waistband region 171 is different from the front waist region 173 because the rear waist region 171 has a length 188 much less than the length 186 of the front waist region 173. At the rear of the article 719, the material 10 is required to be generally unadhered to the base 719 so that the material 10 can provide void volume through the assemblies 12 facing the base 719 to provide enhanced absorption and storage of fecal matter that is expelled. into the rear region of the article 719 near the rear edge 27 of the material 10. Accordingly, the length 188 is preferably about 10% less than the total length of the material 10, or more preferably about 7.5% less, or about 5% less, or about 2 .5% less than the overall length of the material 10. In some preferred embodiments, the length 188 is preferably about 2% greater than the overall length of the material 10. The rear waist bonding region 171 generally functions to ensure that the rear edge 27 of the material 10 is bonded to the base 719.

In fig. 13 depicts the material 10 separated from the article 710, as well as an exemplary binding configuration that may be used to bind the material 10 to the body 719 of the absorbent article 710. As shown in FIG. 13, in addition to bonding regions 171, 173 (both regions 171 and 173 are shown in FIG. 13 without shading to more clearly illustrate other features in FIG. 13), material 10 may be further bonded to body-facing liner material 728 in side regions. 26a, 26b with adhesive bonds 175a, 175b.

In some manufacturing processes to form an article 710 containing material 10, an adhesive may be applied to the body-facing liner 728 before bringing the material 10 to the body-facing liner 728 to form bonds 175a, 175. Accordingly, in such embodiments it may be important such that the adhesive bonds 175a, 175b have widths 177 generally smaller than the widths 31a, 31b of the side zones 26a, 26b of material 10. In some embodiments, the widths 177 can be from about 50% to about 90%, or from about 60% to about 80 % widths 31a, 31b of the side zones 26a, 26b. Although they are shown to extend the full length of the material 10, the adhesive bonds 175a, 175b may extend only about 80% to about 97.5%, or about 85% to about 95% of the total length of the material 10.

The width 177 is less than the widths 31a, 31b, allowing for some inaccuracy in the desired placement of the material 10 when brought into bonding with the liner material 728, with respect to the alignment of the side zones 26a, 26b and the adhesive applied to the liner material 728 forming the bonds 175a, 175b. If the widths 177 are too large, conventional process variations may cause the material 10 to be misaligned with the liner material 728 sufficiently large to cause the adhesive used to form the bonds 175a, 175b and applied to the liner material 728 to overlap the perforated area 16 of the material 10 or is not covered by the side zones 26a and/or 26b of the material 10. Such overlap or lack of coverage of the exposed adhesive may result in the adhesive being exposed through the openings 24 or otherwise, which may also result in the adhesive undesirably bonding to parts of the article 710 other than from material 10.

It is also important to balance the additional amount of adhesive forming the bonds 175a, 175b to ensure commensurate layer strength between the material 10 and the liner material 728, as well as no adhesive bleed due to the relative openness of the side zones 26a, 26b. It has been found that the additional amounts of adhesive used to form the adhesive bonds 175a, 175b should be greater than about 6.0 gsm ^or greater than about 6.5 ^gsm and less than about 13 gsm ^or less than about 12 g/ ^m2 . These additional amounts of adhesive have been found to provide sufficient layer strength between the material 10 and the liner material 728 such that the material 10 does not peel off from the liner material 728 during manufacture or use, and no adhesive bleed occurs in the side areas 26a, 26b.

In some particular embodiments, the material 10 may be bonded to the liner material 728 by at least adhesive bonds 175a, 175b to form front and/or back waist bond regions 173, 171. For example, material 10 may be bonded to liner material 728 by adhesive bonds 175a, 175b before bonding the laminate of materials 10 and 728 to each other through all bonding regions 171, 173. This may be the case when the binding regions 171, 173 are formed by mechanical links.

In at least some of these embodiments, the formation of one or more additional bonds may be required before the formation of binding regions 171, 173. As an example, when material 10 is bonded to liner material 728 in a high speed manufacturing process via bonds 175a, 175b before forming bond regions 171, 173, the leading edge 25 or 27 of material 10 in the processing direction may undesirably fold back before forming regions 171. 173 bindings.

For these reasons, some contemplated bonding configurations connecting material 10 to liner material 728 include at least one additional bond 179 or 181. In some embodiments, only one bond 179 or 181 may be formed depending on which end, 25 or 27, the material 10 represents the leading end in the processing direction. In other embodiments, both bonds 179 and 181 may be formed. In some embodiments, bonds 179 and/or 181 may be formed in conjunction with adhesive bonds 175a, 175b, or at least before bonding regions 171 and/or 173 are formed. These additional bonds 179 and/or 181 help ensure that the leading edge 25 or 27 of the material 10 will be located in a flat state against the spacer material 728 when forming the binding regions 171, 173 or both, the leading edge and the trailing edge 25 and 27, in direction of processing when forming both bonds 179 and 181.

In some embodiments, the additional bond or bonds 179 and/or 181 may be adhesive bonds. In some embodiments, the bonds 179 and/or 181 may at least partially overlap the corresponding front or back waist bond regions 173, 171. In additional embodiments, the bonds 179 and/or 181 may completely overlap the front waist and/or back waist tie regions 173, 171.

If links 179 and/or 181 are present, links 179 and/or 181 may comprise leading and trailing edges 190, 192 and 194, 196, respectively. Links 179 and/or 181 may also have lengths of 193 and 191, respectively. In general, the bond 179 or 181 may primarily act to attach the leading edge 25 or 27 in the processing direction to the liner material 728 to allow subsequent formation of the bond region 171 or 173. However, if both bonds 179 and 181 are present, the bonds 179, 181 may act to attach the leading and trailing edges of the material 10 in the processing direction, such as edges 25 and 27, to the liner material 27 before forming bond regions 171, 173. Accordingly, the lengths 191, 193 may be relatively short. In some embodiments, lengths 191 and/or 193 may be from about 1.0 mm to about 5.0 mm, or from about 2.0 mm to about 5.0 mm, or from about 3.0 mm to about 5.0 mm. Such relatively short lengths 191 and/or 193 may be particularly useful when the bonds 179 and/or 181 are adhesive bonds.

If the bonds 179 and/or 181 are adhesive bonds, the rear and/or leading edges 192, 194 of the bonds 179, 181, respectively, may be set distances 182, 184, respectively, from the rear edge 27 and leading edge 25 of the material 10, as shown in FIG. 13. Although it may be desired that the distances 182 and/or 184 be as small as possible, the distances 182 and/or 184 can typically be from about 2.0 mm to about 5.0 mm, or from about 2.5 mm to about 5.0 mm. .0 mm, or from about 2.5 mm to about 4.0 mm. If the bonds 179 and/or 181 are adhesive bonds, such offsets from the trailing and leading edges 27, 25 of the material 10 help ensure that normal alignment changes in a high speed absorbent article manufacturing process do not cause the adhesive forming the bonds 179 and /or 181 becomes undesirably exposed beyond the edges 25 and/or 27 of the material 10.

As shown in FIG. 13, the bonds 179, 181 extend through the perforated zone 16 of the material 10. If the bonds 179, 181 are adhesive bonds, it is important that the additional amounts of adhesive be relatively small to prevent glue bleed through the holes 24 of the perforated zone 16. Such adhesive bleed may cause unwanted bonding between parts of the article 710. It has been found that the additional amount of adhesive for adhesive bonds 179 and/or 181 should be from about 10 g/m ² to about 40 g/m ² or from about 10 g/m ² to about 35 g/ m ² , or from about 15 g/m ² to about 35 g/m ² .

Although, in embodiments where both bonds 179, 181 are formed, the bond 179 or 181 connecting the leading edge 25 or 27 of the material 10 during manufacture to the spacer material 728 may contain a greater additional amount than the other of the bonds 179, 181. For example, in a high-speed manufacturing process, the leading edge 25 or 27 of the material 10 is subjected to greater forces than the trailing edge 25 or 27. Accordingly, the bond 179, 181 that connects the leading edge 25 or 27 to the spacer material 728 may be required to be relatively stronger than the bond 179, 181 that connects the trailing edge 25 or 27 to the cushion material 728. In these embodiments, the bond 179 or 181 that bonds the leading edge 25 or 27 to the cushion material 728 may contain an additional amount of about 15 gsm ² to about 40 g/m ² or from about 25 g/m ² to about 35 g/m ² . By comparison, another of the links 179, 181 that connects the trailing edge 25 or 27 of the material 10 to the liner material 728 may contain an additional amount that is greater than about 5 ^gsm but less than about 15 ^gsm .

Other contemplated binding configurations may include a configuration comprising bonds 173, 175a and 175b along with binding region 173 only or bond 179 only. Additionally, contemplated binding configurations may include a configuration containing bonds 175a and 175b along with binding region 173 and bond 181 only. Other further contemplated binding configurations may include a configuration containing bonds 175a and 175b along with both bonds 179 and 181, but without binding regions 171, 173.

Waist Sealer

In an embodiment, the absorbent article 410 may have one or more waist sealing elements 454. In fig. 9 and 10 show a preferred embodiment of a waist seal 454 on an absorbent article 410, such as a diaper, where the waist seal 454 may be located in the rear waist region 414. In some embodiments, the waist seal 454 may be located in the front waist region 412. The waist seal 454 may be located on the body facing surface 419 of the body 411. The waist seal 454 may be coupled to the body 411 such that a portion of the waist seal 454 is freely movable relative to the body 411 and may form a pocket to aid retention. body secretions.

The waist seal 454 may be composed of a variety of materials. In a preferred embodiment, the waist seal 454 may be composed of spunbond-meltblown-spunbond (“SMS”) material. However, it is contemplated that the waist seal 54 may be composed of other materials, including, but not limited to, spunbond film-spunbond (“SFS”), bonded carded web (“BCW”), or any nonwoven material. In some embodiments, the waist seal 454 may be composed of a laminate containing more than one of these exemplary materials or other materials. In some embodiments, the waist seal 454 may be comprised of a liquid impermeable material. In some embodiments, the waist seal 454 may be comprised of a material coated with a hydrophobic coating. In some embodiments, the waist seal 54 may include elastic material to provide additional fit and retention characteristics of the absorbent article 10. In such an embodiment, suitable elastic materials may include, but are not limited to, sheets, strips, or tapes of natural rubber, synthetic rubber, or thermoplastic elastomeric polymers. Elastic materials can be stretched and bonded to a substrate, bonded to an assembled substrate, or bonded to a substrate and then made elastic or compressed, for example by applying heat, so that elastic tensile forces are transferred to the substrate. However, it should be understood that the waist seal 454 may be omitted from the absorbent article 410 without departing from the scope of the present invention.

Fastening system

In one embodiment, absorbent article 410 may include an attachment system. The fastening system may include one or more rear fastenings 491 and one or more front fastenings 492. The embodiments shown in FIGS. 9 and 10 depict an embodiment with a single front fastener 492. Portions of the fastening system may be included in the front waist region 412, the rear waist region 414, or both.

The fastening system may be configured to secure the absorbent article 410 around the wearer's waist in a secured state, as shown in FIG. 9, and helping to hold the absorbent article 410 in place during use. In an embodiment, the rear fasteners 491 may comprise one or more materials bonded together to form a composite tab, as is known in the art. For example, a complex fastener may consist of a stretch component 494, a nonwoven support layer or hook backing 496, and a fastening component 498, as indicated in FIG. 10.

TEST METHODS

Test method based on node analysis

The anisotropy of the fibers at the nodes 12 can be determined using the image analysis measurement method described herein. This test method also measures the height of the nodes, as well as the percentage of fibers and voids in the node 12.

In this context, fiber anisotropy is considered for a plurality of nodes 12 of each respective material. Typically, in the image analysis method, a numerical anisotropy value is determined from a cross-sectional image of the node 12 using a special image analysis measurement parameter called anisotropy. The anisotropy of node 12 can be measured using X-ray computed microtomography (also known as micro-CT) to obtain a non-destructive image, followed by image analysis techniques to detect fiber components, and then measuring the anisotropy of said components only in areas of node 12. An image analysis algorithm performs the detection , image processing and measurement, and transmits the data digitally to a spreadsheet database. The resulting measurement data is used to compare the anisotropy of different structures containing fiber components of the nodes 12.

The method for determining anisotropy in the fibers of the nodes of each structure includes the first stage of obtaining digital images of X-ray computed microtomography of the sample. These images were acquired using a SkyScan 1272 computed microtomography system available from Bruker microCT (2550 Contih, Belgium). The sample is attached to the mounting device provided by Bruker with the SkyScan 1272 system so that it does not move under its own weight during the scanning process. During the scanning process, the following SkyScan 1272 conditions are used:

- Camera pixel size (µm)=9.0

- Source voltage (kV)=35

- Source current (µA)=225

- Image pixel size (µm)=6.0

- Image format=TIFF

- Depth (bits)=16

- Rotation step (degrees) = 0.10

- Use 360 rotation=NO

- Frame averaging=ENABLED (6)

- Random movement=ON (1)

- Correction for uniform field illumination=ON

- Filter=No filter

Once scanning of the sample is completed, the resulting set of images is then reconstructed using the NRecon program provided with the SkyScan 1272 CT microtomography system. Although reconstruction parameters may be somewhat sample dependent and should be known to one skilled in the art, the following parameters should provide basic guidelines for analyzing specialist:

- Image file type=BMP

- Pixel size (µm)=6.00

- Smoothing=1 (Gaussian)

- Correction of artifacts “ringing”=10

- Beam tightening correction (%)=10

Once the reconstruction is complete, the resulting image dataset is ready to extract cross-sectional image slices using a Bruker SkyScan software package called DataViewer. After loading the entire dataset of reconstructed images into the DataViewer, the CT microtomography analyst must then select and extract cross-sectional image slices located at or near the centers of the nodes present in each respective sample. For each selected image, one center-aligned node 12 should be obtained. For a typical sample, this process will result in 4-6 images, and 4-6 nodes 12 will be available for analysis. The analyzer then renumbers the images sequentially (e.g., 1 , 2, 3, etc.), changing the numbers in the image file name extensions.

After acquiring and re-numbering CT microtomography images of cross sections of each sample, anisotropy measurements can be made using image analysis software.

The image analysis software platform used to perform anisotropy measurements is QWIN Pro (version 3.5.1), available from Leica Microsystems, Heerbrugg, Switzerland.

Thus, a method for determining the anisotropy of a given sample includes the step of performing multiple anisotropy measurements on a set of computed microtomography images. More specifically, an image analysis algorithm is used to read and process images and perform measurements using the Quantimet Interactive Programming User System (QUIPS) language. The image analysis algorithm is reproduced below.

DEFINING VARIABLES and OPENING FILES

The following lines indicate the location on the computer where the data is sent

Open File (C:\Data\94054 - Nhan (patent)\z-micro-ct data.xls, channel #1)

PauseText("Enter the number of the final image in the set.")

Input (IMAGES)

SAMPLE ID AND INSTALLATION

Enter Results Header

File Results Header (channel #1)

File Line (channel #1)

Measure frame (x 31, y 61, Width 1737, Height 793)

Image frame ( x 0, y 0, Width 1768, Height 854 )

-- Calvalue 6.0 um/pixel

CALVALUE = 6.0

Calibrate (CALVALUE CALUNITS$ per pixel)

-- Enter image prefix name of set of images to analyze

PauseText("Enter image file prefix name.")

Input ( TITLE$ )

File("Rep. #", channel #1)

File ("% Fiber", channel #1)

File ("%Voids", channel #1)

File ("Height (um)", channel #1)

File ("Anisotropy", channel #1)

File Line ( channel #1 )

For ( REPLICATE = 1 to IMAGES, step 1 )

Clear Accepts

IMAGE ACQUISITION AND DETECTION

ACQOUTPUT = 0

The next two lines indicate the location on the computer of the CT microtomography images read during the image analysis process.

ACQFILE$ = "C:\Images\94054 - Nhan\Z-slices\"+TITLE$+""+STR$(REPLICATE)+".jpg"

Read image ( from file ACQFILE$ into ACQOUTPUT )

Color Transform (Mono Mode)

Gray Transform ( WSharpen from Image0 to Image1, cycles 3, operator Disc )

Detect ( whiter than 64, from Image1 into Binary0 )

IMAGE PROCESSING

PauseText("Select region of interest for analysis.")

Binary Edit [PAUSE] ( Accept from Binary0 to Binary1, nib Fill, width 2 )

Binary Amend ( Close from Binary1 to Binary2, cycles 30, operator Disc, edge erode on )

Binary Identify ( FillHoles from Binary2 to Binary3 )

Binary Amend ( Open from Binary3 to Binary4, cycles 40, operator Disc, edge erode on )

PauseText ( "Clean up any over extended ROI areas." )

Binary Edit [PAUSE] ( Reject from Binary4 to Binary5, nib Fill, width 2 )

PauseText ( "Draw vertical lline thru the thickest region binary." )

Binary Edit [PAUSE] ( Accept from Binary5 to Binary7, nib Rect, width 2 )

Binary Logical ( C = A AND B : C Binary6, A Binary1, B Binary5 )

MEASURE AREAS OF ANALYSIS

--Analysis Region Fiber Area

MFLDIMAGE = 6

Measure field ( plane MFLDIMAGE, into FLDRESULTS(2), statistics into FLDSTATS(7,2) )

Selected parameters: Area, Anisotropy

FIBERAREA = FLDRESULTS(1)

ANISOTROPY = FLDRESULTS(2)

--Analysis Region Area

MFLDIMAGE = 5

Measure field ( plane MFLDIMAGE, into FLDRESULTS(1), statistics into FLDSTATS(7,1) )

Selected parameters: Area

ROIAREA = FLDRESULTS(1)

PERCFIBER = FIBERAREA/ROIAREA*100

PERCVOIDS = 100-PERCFIBER

-- Measure Node Height

Measure feature ( plane Binary7, 8 ferets, minimum area: 24, gray image: Image0 )

Selected parameters: X FCP, Y FCP, Length

LENGTH = Field Sum of ( PLENGTH(FTR) )

OUTPUT

File ( REPLICATE, channel #1, 0 digits after '.' )

File ( PERCFIBER, channel #1, 1 digit after '.' )

File ( PERCVOIDS, channel #1, 1 digit after '.' )

File ( LENGTH, channel #1, 1 digit after '.' )

File ( ANISOTROPY, channel #1, 2 digits after '.' )

File Line ( channel #1 )

Next(REPLICATE)

Close File (channel #1)

END

The QUIPS algorithm is performed using the QWIN Pro software platform. First, the analyzer is prompted to enter the number of images in the set for a particular sample. The analyzer is then prompted to enter a set of sample identification information, which is sent to an EXCEL file.

The analyzer is then prompted through an interactive command window and input window to enter the image file prefix of the CT microtomography images being analyzed. After this step, all subsequent images for a given sample will be automatically read by the image analysis algorithm described above.

The analyzer is then provided with prompts to manually select, using a computer mouse, an area of interest for analysis. The entire assembly should be carefully selected to include tapered sections right down to the base plane 18 of the material.

After several stages of image processing, which will occur automatically, the analyzer will again be prompted to clean up any areas that extend beyond the region of interest (ROI). This is done by using the computer mouse, and by enabling and disabling the binary overlay by simultaneously using the "control" and "b" keys on the computer keyboard. After this stage, the binary image should only cover the node.

Finally, the analyzer will be provided with prompts to use the computer mouse to draw a vertical line through the area with the highest height on the binary image. This line will be used by a computer algorithm to measure the height of node 12.

The process of selecting an area of interest on node 12, clearing out areas outside it, and drawing a vertical line through the highest height region of node 12 will be repeated until all images for a particular sample have been analyzed.

Once all images have been analyzed, the following measurement parameter data will be located in the corresponding EXCEL file:

Copy number

% fiber

% voids

Height

Anisotropy

For each of these parameters, 4-6 values will be listed in the columns. To compare anisotropy values between samples, the data in the column labeled "Anisotropy" can be compared between different samples by performing a Student's t-analysis at 90% confidence level.

Test method based on analysis of a material sample

The test method described herein, based on analysis of a material sample, can be used to determine the percentage open area in a given sample of nonwoven fabric 10. In this context, the percentage open area is considered to be the percentage of the area of the nonwoven fabric through which light passing from light source. Typically, in this image analysis method, a numerical percentage open area value is determined for a material using specific image analysis measurement parameters such as area. This test method and equipment also provides the ability to measure the size of the hole 24, the roundness of the hole 24, the aspect ratio of the hole 24, the two-dimensional area of the node 12, the density of the nodes 12 and the distance between them. This test method involves taking two separate digital images of the sample.

Installation and determination of sample analysis of the perforated zone of the material

An exemplary setup for obtaining images of the perforated area is representatively illustrated in FIG. 15. Specifically, a CCD video camera 70 (for example, a Leica DFC 300 FX video camera available from Leica Microsystems of Herbrugg, Switzerland) is mounted on a standard tripod 72, such as the standard Polaroid MP-4 Land Camera tripod previously available for purchased from the Polaroid Resource Center in Cambridge, Massachusetts, and is currently available on eBay. A standard tripod 72 is attached to a macro viewer 74, such as a KREONITE macro viewer available from Dunning Photo Equipment Inc. with an office in Bixby, Oklahoma. The automatic platform 76 is placed on the top surface of the macro viewing device 74. The automatic platform 76 is used to automatically change the position of a predetermined sample for frame selection by the camera. A suitable automated platform 76 is the Model H112, available for purchase from Prior Scientific Inc. with an office in Rockland, Massachusetts.

The sample (not shown in FIG. 15) is placed on an automated platform 76 of the Leica Microsystems QWIN Pro Image Analysis system, under the optical axis of a 60 mm lens 78, such as a Nikon AF Micro Nikkor, with an aperture setting of 4, manufactured by Nikon Corporation with offices in Tokyo, Japan. Lens 78 is attached to camera 70 using a c-lens adapter. The distance from the front of the lens 78 to the sample is 55 cm. The sample is laid horizontally on the platform surface 80 and any wrinkles are removed by gently stretching it and/or securing it to the platform surface 80 using clear adhesive tape on its outer edges. The sample surface is illuminated with incident fluorescent light delivered by a 40-watt, 16-inch diameter 82 Circline fluorescent lamp, for example, manufactured by General Electric Company of Boston, Massachusetts. The lamp 82 is contained in a clamp which is positioned such that it is centered above the sample and is approximately 3 cm above the surface of the sample. The illumination level of lamp 82 is controlled using a variable autotransformer (not shown) type 3PN1010, available from Staco Energy Products Co. with an office in Dayton, Ohio. Transmitted light is also delivered to the sample from underneath the automated platform by a bank of four 2-foot, dimmable, 2-foot EMC 84 LED tube lamps that are available from Fulight Optoelectronic Materials, LLC. The LED lamps 84 are covered with a diffusion plate 86. The diffusion plate 86 is inserted into and forms a part of the top surface 88 of the macro viewer 74. A black mask 90 having an opening 92 measuring 3 inches by 3 inches is placed over the light source. The hole 92 is located such that it is centered under the optical axis of the system of camera 70 and lens 78. The distance D3 from the hole 92 of the fluorescent lamp to the surface 80 of the automatic platform 76 is approximately 17 cm. The illumination level of the group of fluorescent lamps is also controlled by the unit control (not shown), configured to dim the lighting of LED lamps.

The image analysis software platform used to perform measurements of percentage open area and perforation size is QWIN Pro (version 3.5.1), available for purchase from Leica Microsystems based in Heerbrugg, Switzerland. Alternatively, LAS Macro Editor, the next generation of software after QWIN Pro, can be used to perform the analysis. The system and images are also precisely calibrated using QWIN software and a standard ruler with measurement marks to at least one millimeter. Calibration is performed in the horizontal dimension of the video camera image. Units of millimeters per pixel are used for calibration.

Thus, a method for determining the percentage open area and hole size of a given sample includes the step of performing measurements on a transmitted light image. Specifically, an image analysis algorithm is used to acquire and process images and perform measurements using the Quantimet User Interactive Programming System (QUIPS) language. The image analysis algorithm is reproduced below. For clarity, references in the algorithm to “pillars” or “protrusions” refer to the nodes 12 for the nonwoven fabric 10, and references to “open areas” or “perforations” refer to the holes 24 for the nonwoven fabric 10.

DEFINING VARIABLES AND OPENING FILES

The following lines indicate the location on the computer where the data is sent

Open File (C:\Data\94054 - Nhan (patent)\data.xls, channel #1)

TOTCOUNT = 0

TOTFIELDS = 0

MFRAMEH = 875

MFRAMEW = 1249

SAMPLE ID AND INSTALLATION

Configure (Image Store 1392 x 1040, Gray Images 81, Binaries 24)

Enter Results Header

File Results Header ( channel #1 )

File Line ( channel #1 )

PauseText("Enter sample image prefix name now.")

Input ( TITLE$ )

PauseText("Set sample into position.")

Image Setup DC Twain [PAUSE] ( Camera 1, AutoExposure Off, Gain 0.00, ExposureTime 34.23 msec, Brightness 0, Lamp 38.83 )

Measure frame ( x 74, y 110, Width 1249, Height 875 )

Image frame ( x 0, y 0, Width 1392, Height 1040 )

-- Calvalue = 0.0377 mm/px

CALVALUE = 0.0377

Calibrate ( CALVALUE CALUNITS$ per pixel )

FRMAREA = MFRAMEH*MFRAMEW*(CALVALUE**2)

Clear Accepts

For ( SAMPLE = 1 to 1, step 1 )

Clear Accepts

File ( "Field No.", channel #1, field width: 9, left justified )

File ("% Open Area", channel #1, field width: 7, left justified)

File ( "Bump Density", channel #1, field width: 13, left justified )

File ( "Bump Spacing", channel #1, field width: 15, left justified )

File Line ( channel #1 )

Stage (Define Origin)

Stage ( Scan Pattern, 1 x 5 fields, size 82500.000000 x 39000.000000 )

IMAGE ACQUISITION I - Protrusion Localization

For (FIELD = 1 to 5, step 1)

Measure frame ( x 74, y 110, Width 1249, Height 875 )

Display ( Image0 (on), frames (on,on), planes (off,off,off,off,off,off), lut 0, x 0, y 0, z 1, Reduction off )

PauseText ( "Ensure incident lighting is correct (WL = 0.88 - 0.94) and acquire image." )

Image Setup DC Twain [PAUSE] ( Camera 1, AutoExposure Off, Gain 0.00, ExposureTime 34.23 msec, Brightness 0, Lamp 38.83 )

Acquire ( into Image0 )

IDENTIFICATION - Protrusions only

PauseText ( "Ensure that threshold is set at least to the right of the left gray-level histogram peak which corresponds to the 'land' region." )

Detect [PAUSE] ( whiter than 129, from Image0 into Binary0 delineated )

BINARY IMAGE PROCESSING

Binary Amend ( Close from Binary0 to Binary1, cycles 10, operator Disc, edge erode on )

Binary Identify ( FillHoles from Binary1 to Binary1 )

Binary Amend ( Open from Binary1 to Binary2, cycles 20, operator Disc, edge erode on )

Binary Amend ( Close from Binary2 to Binary3, cycles 8, operator Disc, edge erode on )

PauseText ( "Toggle <control> and <b> keys to check projection detection and correct if necessary." )

Binary Edit [PAUSE] ( Reject from Binary3 to Binary3, nib Fill, width 2 )

Binary Logical ( copy Binary3, inverted to Binary4 )

IMAGE ACQUISITION 2 - % Open Area and Perforation Size

Measure frame ( x 74, y 110, Width 1249, Height 875 )

Display ( Image0 (on), frames (on,on), planes (off,off,off,off,off,off), lut 0, x 0, y 0, z 1, Reduction off )

PauseText ( "Turn off incident light & ensure transmitted lighting is correct (WL = 0.95) and acquire image." )

Image Setup DC Twain [PAUSE] ( Camera 1, AutoExposure Off, Gain 0.00, ExposureTime 34.23 msec, Brightness 0, Lamp 38.83 )

Acquire ( into Image0 )

ACQFILE$ = "C:\Images\94054 - Nhan\"+TITLE$+"_"+STR$(FIELD)+".jpg"

Write image ( from ACQOUTPUT into file ACQFILE$ )

DETECTION - Open areas only

Detect ( whiter than 127, from Image0 into Binary10 delineated )

BINARY IMAGE PROCESSING

Binary Amend ( Close from Binary10 to Binary11, cycles 5, operator Disc, edge erode on )

Binary Identify ( FillHoles from Binary11 to Binary12 )

Binary Amend ( Open from Binary12 to Binary13, cycles 10, operator Disc, edge erode on )

Binary Identify ( EdgeFeat from Binary13 to Binary14 )

PauseText("Ensure apertures are detected accurately.")

Binary Edit [PAUSE] ( Reject from Binary14 to Binary14, nib Fill, width 2 )

FIELD MEASUREMENTS - % Open Area, Bump Density & Spacing

-- % open area

MFLDIMAGE = 10

Measure field ( plane MFLDIMAGE, into FLDRESULTS(1), statistics into FLDSTATS(7,1) )

Selected parameters: Area%

Field Histogram #1 ( Y Param Number, X Param Area%, from 0. to 60., linear, 20 bins )

PERCOPENAREA = FLDRESULTS(1)

-- bump density & spacing

MFLDIMAGE = 3

Measure field ( plane MFLDIMAGE, into FLDRESULTS(5), statistics into FLDSTATS(7,5) )

Selected parameters: Area, Intercept H, Intercept V, Area%,

Count/Area

BUMPDENSITY = FLDRESULTS(5)

MNSPACE1 = (FRMAREA-FLDRESULTS(1))/(FLDRESULTS(2)+FLDRESULTS(3))/2

Field Histogram #2 ( Y Param Number, X Param MNSPACE1, from 0. to 50., linear, 25 bins )

File ( FIELD, channel #1, 0 digits after '.' )

File ( PERCOPENAREA, channel #1, 1 digit after '.' )

File (BUMPDENSITY, channel #1, 1 digit after '.' )

File ( MNSPACE1, channel #1, 1 digit after '.' )

File Line ( channel #1 )

ELEMENT MEASUREMENTS - Dimensions of perforations and posts

-- Bump Size

Measure feature ( plane Binary3, 8 ferets, minimum area: 24, gray image: Image0 )

Selected parameters: Area, X FCP, Y FCP, EquivDiam

Feature Histogram #1 ( Y Param Number, X Param Area, from 1. to 100., logarithmic, 20 bins )

Feature Histogram #2 ( Y Param Number, X Param EquivDiam, from 1. to 100., logarithmic, 20 bins )

-- Aperture Size

Measure feature ( plane Binary14, 8 ferets, minimum area: 24, gray image: Image0 )

Selected parameters: Area, X FCP, Y FCP, Roundness, AspectRatio,

EquivDiam

Feature Histogram #3 ( Y Param Number, X Param Area, from 1. to 100., logarithmic, 20 bins )

Feature Histogram #4 ( Y Param Number, X Param EquivDiam, from 1. to 100., logarithmic, 20 bins )

Feature Histogram #5 ( Y Param Number, X Param Roundness, from 0.8999999762 to 2.900000095, linear, 20 bins )

Feature Histogram #6 ( Y Param Number, X Param AspectRatio, from 1. to 3., linear, 20 bins )

Stage ( Step, Wait until stopped + 1100 msecs )

Next (FIELD)

Next (SAMPLE)

File Line ( channel #1 )

File Line ( channel #1 )

OUTPUT OF HISTOGRAMS OF ELEMENTS

File ( "Bump Size (area - sq. mm)", channel #1 )

File Line ( channel #1 )

File Feature Histogram Results ( #1, differential, statistics, bin details, channel #1 )

File Line ( channel #1 )

File Line ( channel #1 )

File ( "Bump Size (ECD - mm)", channel #1 )

File Line ( channel #1 )

File Feature Histogram Results ( #2, differential, statistics, bin details, channel #1 )

File Line ( channel #1 )

File Line ( channel #1 )

File ( "Aperture Size (area - sq. mm)", channel #1 )

File Line ( channel #1 )

File Feature Histogram Results ( #3, differential, statistics, bin details, channel #1 )

File Line ( channel #1 )

File Line ( channel #1 )

File ( "Aperture Size (ECD - mm)", channel #1 )

File Line ( channel #1 )

File Feature Histogram Results ( #4, differential, statistics, bin details, channel #1 )

File Line ( channel #1 )

File Line ( channel #1 )

File ("Aperture Roundness", channel #1)

File Line ( channel #1 )

File Feature Histogram Results ( #5, differential, statistics, bin details, channel #1 )

File Line ( channel #1 )

File Line ( channel #1 )

File ("Aperture Aspect Ratio", channel #1)

File Line ( channel #1 )

File Feature Histogram Results ( #6, differential, statistics, bin details, channel #1 )

File Line ( channel #1 )

File Line ( channel #1 )

Close File ( channel #1 )

END

The QUIPS algorithm is performed using the QWIN Pro software platform. The analyzer is first provided with prompts to enter sample setup information, which is sent to the EXCEL file.

The analyzer then enters the image file prefix name corresponding to the sample ID. It will be used by the algorithm to save the images obtained during the analysis to the specified file location. The analyzer is then guided through the live image setup window on the computer monitor to place the sample on the automated platform. The specimen should be laid horizontally and force should be carefully applied to its edges to remove any large folds that may be present. At this point, the 82 Circline fluorescent lamp can be turned on to assist in positioning the sample. The analyst is then provided with guidance on setting the 82 Circline fluorescent lamp for incident illumination using an adjustable autotransformer to achieve a white level of approximately 0.9. The lamps under the platform for transmitted light should either be turned off at this point or masked using a piece of light-blocking black construction paper placed over a 3" x 3" 92 hole.

The analyzer is then provided with prompts to ensure that the detection threshold is set to an appropriate level to detect nodes 12 using a “detection window” that is displayed on a computer monitor screen. Typically, the threshold is set using the white mode at a point approximately near the middle of the range on the 8-bit gray scale (for example, 127). If necessary, the threshold level can be adjusted up or down so that the resulting binary image optimally covers the nodes 12 shown in the resulting image.

After the algorithm automatically performs several stages of binary image processing on the identified binary image of nodes 12, the analyzer will be given the opportunity to re-check the identification of nodes and correct any inaccuracies. To recheck the detection of nodes against the underlying acquired grayscale image, the analyzer can simultaneously press both the “control” and “b” keys. If necessary, the analyzer can choose from a selection of binary image editing tools (eg draw, undo, etc.) to make any minor adjustments. If care is taken to ensure proper coverage and detection at the previously described stages, few or no corrections will be needed at this point.

The analyst is then provided with prompts to turn off the 82 Circline fluorescent lamp for incident illumination and either turn on the lamps under the platform for transmitted illumination or remove the light-blocking mask. The lamps under the platform for transmitted light are adjusted using the LED power control to a white level of approximately 0.95. At this point, the image focus can be optimized for the perforated zone 16 of the material 10 containing the holes 24.

After performing additional operations on the resulting individual binary images for holes 24, the algorithm will provide hints to the analyzer to recheck the detection of holes 24 against the underlying halftone image. If necessary, the analyzer can choose from a selection of binary image editing tools (eg draw, undo, etc.) to make any minor adjustments.

The algorithm will then automatically take measurements and output the data to a designated file in the form of an EXCEL spreadsheet.

Once the data is transmitted, the algorithm will control the movement of the automatic platform to the next field of view, and the process of turning on the 82 Circline fluorescent lamp for incident light illumination and blocking the illumination under the platform for transmitted light illumination will begin again. This process will be repeated four times such that for each sample instance there will be five sets of data from five separate FOV images.

After completing the analysis, taking measurements and transferring the measurement parameters data, the EXCEL file will contain the following data:

Open area in percentage

Knot density (number per square meter)

Distance between nodes (mm)

Node size (one histogram for area in ^mm2 , and one histogram for equivalent circle diameter in mm)

Size of perforations (one histogram for area in ^mm2 , and one histogram for equivalent circle diameter in mm)

Roundness of perforations

Perforation aspect ratio

The final mean for the sample distribution is usually based on an N=5 analysis from five separate instances of sample parts. Comparison of percentage open area, hole size 24 (perforations) and other parameters obtained by the algorithm for different samples can be performed using Student's T-analysis with a confidence level of 90%.

Setting and determining the open area in percentage of the side zone of the material

The setup for imaging the side zones of the material is similar to the setup for imaging the perforated zone of the material, with a few minor differences detailed below.

The camera, lens, support structure and platform used to capture images of the side zones of the material, as well as the settings for them, are the same as in the section “Setup and Defining the Analysis of the Perforated Zone of the Material” section . However, this installation does not use a viewing device. A sample of the side zone of the material being tested is prepared and placed on the surface 80 of the automatic platform, as in the section "Setup and determination of the analysis of the sample of the perforated zone of material" . However, instead of illuminating the sample surface with incident fluorescent light delivered by a Circline fluorescent lamp, light is transmitted to the sample from the bottom of the sample from a ChromaPro 45 device previously available for purchase from Circle S in Tempe, Arizona, which contains a black mask with a 3" x 3" hole. superimposed on its surface.

As in the "Setting up and defining a material perforated zone sample analysis" section, the image analysis software platform used to perform the percentage open area measurement for the material side zones is QWIN Pro (Version 3.5.1), available for purchase from Leica Microsystems . Alternatively, LAS Macro Editor, the next generation of software after QWIN Pro, can be used to perform the analysis. The system and images are also precisely calibrated using QWIN software and a standard ruler with measurement marks to at least one millimeter. Calibration is performed in the horizontal dimension of the video camera image. Units of millimeters per pixel are used for calibration.

In Setting and Defining the Material Side Zone Percentage Open Area , when running QWIN Pro, the light level is set to 0.95 using the white level function in QWIN Pro to adjust the light output for the ChromaPro light output. The QWIN Pro software is additionally configured to move the Prior automatic platform so that six images are automatically acquired and measured from each side of the material sample, resulting in a total of twelve measurements.

Thus, a method for determining the percent open area of a side zone includes the step of performing measurements on a transmitted light image. Specifically, an image analysis algorithm is used to acquire and process images and perform measurements using the Quantimet User Interactive Programming System (QUIPS) language. The image analysis algorithm is reproduced below.

DEFINING VARIABLES AND OPENING FILES

The following lines indicate the location on the computer where the data is sent

Open File ( D:\Data\103470 - Nhan\data.xls, channel #1 )

TOTCOUNT = 0

TOTFIELDS = 0

MFRAMEH = 875

MFRAMEW = 1249

SAMPLE ID AND INSTALLATION

Configure (Image Store 1392 x 1040, Gray Images 81, Binaries 24)

Enter Results Header

File Results Header ( channel #1 )

File Line ( channel #1 )

PauseText("Enter sample image prefix name now.")

Input ( TITLE$ )

Measure frame ( x 511, y 50, Width 446, Height 940 )

Image frame ( x 0, y 0, Width 1392, Height 1040 )

PauseText("Set sample into position.")

Image Setup DC Twain [PAUSE] ( Camera 1, AutoExposure Off, Gain 0.00, ExposureTime 34.23 msec, Brightness 0, Lamp 38.83 )

-- Calvalue = 0.0333 mm/px

CALVALUE = 0.0333

Calibrate ( CALVALUE CALUNITS$ per pixel )

FRMAREA = MFRAMEH*MFRAMEW*(CALVALUE**2)

File ( "Field No.", channel #1, field width: 9, left justified )

File ("% Open Area", channel #1, field width: 7, left justified)

File Line ( channel #1 )

For ( SAMPLE = 1 to 2, step 1 )

Clear Accepts

Stage (Define Origin)

Stage ( Scan Pattern, 1 x 6 fields, size 82500.000000 x 39000.000000 )

For ( FIELD = 1 to FIELDS, step 1 )

ACQUISITION OF IMAGE

ACQOUTPUT = 0

Measure frame ( x 511, y 50, Width 446, Height 940 )

Display ( Image0 (on), frames (on,on), planes (off,off,off,off,off,off), lut 0, x 0, y 0, z 1, Reduction off )

PauseText ( "Turn off incident light & ensure transmitted lighting is correct (WL = 0.95) and acquire image." )

Image Setup DC Twain [PAUSE] ( Camera 1, AutoExposure Off, Gain 0.00, ExposureTime 34.23 msec, Brightness 0, Lamp 38.83 )

Acquire ( into Image0 )

ACQFILE$ = "D:\Images\103470 - Nhan\"+TITLE$+"_"+STR$(FIELD)+".jpg"

Write image ( from ACQOUTPUT into file ACQFILE$ )

DETECTION - Open areas only

Detect ( whiter than 164, from Image0 into Binary10 )

BINARY IMAGE PROCESSING

Binary Amend ( Close from Binary10 to Binary11, cycles 1, operator Disc, edge erode on )

Binary Identify ( FillHoles from Binary11 to Binary12 )

Binary Identify ( EdgeFeat from Binary12 to Binary13 )

FIELD MEASUREMENTS

-- % open area

MFLDIMAGE = 13

Measure field ( plane MFLDIMAGE, into FLDRESULTS(1), statistics into FLDSTATS(7,1) )

Selected parameters: Area%

Field Histogram #1 ( Y Param Number, X Param Area%, from 0. to 5., linear, 20 bins )

Display Field Histogram Results ( #1, horizontal, differential, bins + graph (Y axis linear), statistics )

Data Window (1449, 599, 423, 270)

PERCOPENAREA = FLDRESULTS(1)

File ( FIELD, channel #1, 0 digits after '.' )

File ( PERCOPENAREA, channel #1, 1 digit after '.' )

File Line ( channel #1 )

ELEMENT MEASUREMENTS

-- Aperture Size

Stage ( Step, Wait until stopped + 1100 msecs )

Next (FIELD)

File Line ( channel #1 )

PauseText("Load next replicate now.")

Image Setup DC Twain [PAUSE] ( Camera 1, AutoExposure Off, Gain 0.00, ExposureTime 23.16 msec, Brightness 0, Lamp 38.83 )

Next (SAMPLE)

File Line ( channel #1 )

OUTPUT OF HISTOGRAMS OF ELEMENTS

File ("%Area Histogram", channel #1)

File Line ( channel #1 )

File Line ( channel #1 )

File Field Histogram Results ( #1, differential, statistics, bin details, channel #1 )

Close File ( channel #1 )

END

In the section “Setting and determining the open area in percentage of the side zone of the material,” the QUIPS algorithm is executed using the QWIN Pro software platform. The analyzer is first provided with prompts to enter sample setup information, which is sent to the EXCEL file.

The analyzer then enters the image file prefix name corresponding to the sample ID. It will be used by the algorithm to save the images obtained during the analysis to the specified file location. The analyzer is then guided through the live image setup window on the computer monitor to place the sample on the automated platform. The specimen should be laid horizontally and force should be carefully applied to its edges to remove any large folds that may be present. At this point, the light level should be set to 0.95 using the QWIN Pro white level function to adjust the light output for the ChromaPro light output if this has not already been done. At this point, the image focus can be optimized for the side zone 26a or 26b of the material 10 containing microperforations 81 and/or areas of significantly reduced fiber density 39.

After performing additional operations on the resulting individual binary images for microperforations 81 and/or regions of significantly reduced fiber density 39 , the algorithm will provide hints to the analyzer to recheck the identification of microperforations 81 and/or regions of significantly reduced fiber density 39 relative to the underlying grayscale image. If necessary, the analyzer can choose from a selection of binary image editing tools (eg draw, undo, etc.) to make any minor adjustments.

The algorithm will then automatically take measurements and output the data to a designated file in the form of an EXCEL spreadsheet.

After data transmission, the algorithm will direct the movement of the automatic platform to the next field of view. This process will be repeated six times along each edge of the side zone material sample such that for each sample instance there will be twelve sets of data from twelve separate FOV images.

After completing the analysis, taking measurements and transferring the measurement parameters data, the EXCEL file will contain the following data:

Open area in percentage

The final mean for the sample distribution is usually based on an N=5 analysis from five separate instances of sample parts. Comparison of the percentage open area obtained by the algorithm for different samples can be performed using Student's T-analysis with a confidence level of 90%.

Test to determine compression energy

The compression energy test used herein is a three-cycle compression test, which can be performed to measure the compressive elasticity of projections on a single-layer projection layer. Compressive elasticity is measured by measuring the compressive energy. Typically, the term "compressive energy" refers to the energy required to compress the projection layer from its initial thickness at 5 gram-force (approximately 0.027 kPa) to its final thickness at approximately 1830 gram-force (approximately 10 kPa). Compressive energy is calculated as the area under the compressive stress (force/area) versus linear thickness curve, determined by the initial contact pressure (5 gram-force) and the final contact pressure of approximately 1830 gram-force (approximately 10 kPa).

1. If the nonwoven fabric to be tested forms part of a composite or absorbent article, freeze spraying is used to thoroughly remove the nonwoven fabric.

2. A round test sample is cut from non-woven material using a die with a diameter of 47.8 mm.

3. The upper and lower stainless steel plates are attached to the dynamometer.

4. The top plate has a diameter of 89mm, while the bottom plate has a diameter of 152mm. The top plate is connected to a 100 N load cell, while the bottom plate is connected to the base of the dynamometer.

5. TestWorks Version 4 software provided by MTS is used to monitor the displacement of the top slab and record the load and distance between the two slabs.

6. For the top plate, a slow downward movement and contact with the bottom plate is initiated until the compressive load reaches about 5000 g. At this point, the distance between the two plates is zero.

7. The top plate is then set to move upward (away from the bottom plate) until the distance between the two plates reaches 15 mm.

8. The slider readings shown on the TestWorks Version 4 software are set to zero.

9. The test piece is placed in the center of the bottom plate with the nodes facing the top plate.

10. For the top plate, a descent towards the bottom plate is initiated and compression of the test sample is initiated at a speed of 10 mm/min. The distance the top plate moves is indicated by reading the slider. This is a loading process.

11. Compression should continue until the load exceeds 1830 gram-force (approximately 10 kPa), at which point the plate should reverse direction and move upward at a speed of 10 mm/min until the force will decrease below 5 gram-force. The slab should then reverse its direction of motion and enter a second compression cycle at a rate of 10 mm/min until the load exceeds 1830 gram-force (approximately 10 kPa). Once the load exceeds 1830 gram-force (approximately 10 kPa), the plate should reverse its direction of motion and move upward at a speed of 10 mm/min until the force decreases below 5 gram-force. The slab should then reverse its direction of motion and enter a third compression cycle at a rate of 10 mm/min until a load of 1830 gram-force (approximately 10 kPa) is exceeded. At this moment, the top plate stops moving downwards and returns at a speed of 10 mm/min to its original position, in which the distance between the two plates is 15 mm.

12. The compressive load and the corresponding distance between the two plates during loading and unloading are recorded on a computer using TestWorks Version 4 software provided by MTS.

13. The compressive load is converted to compressive stress by dividing the compressive force by the area of the test specimen, which is 17.94 cm ² .

14. The distance between two slabs at a given compressive stress is the thickness at that particular compressive stress.

15. For each type of test specimen, a total of six test specimens are tested to obtain representative loading and unloading curves for each type of test specimen.

Compression Linearity Test

Compression linearity is measured using the Kawabata Evaluation System KES model FB-3, also available from Kato Tech Company.

This instrument is designed to measure the compressive properties of materials by compressing a sample between two pistons. To measure compression properties, the top piston is lowered onto the sample at a constant speed until it reaches a maximum specified force. The displacement of the upper piston is detected by a potentiometer. The amount of pressure required to compress the sample (P, gf/ ^cm2 ), depending on the thickness (displacement) of the material (T, mm), is displayed as a graph on the computer screen. For all materials in this study, the following instrument settings were used:

Sensitivity=2×5

Gear (speed)=1mm/50s

Fm set=5.0

Selection of stroke length=maximum 5 mm

Compression area=2 cm ²

Time span=standard

Maximum compression force=50 gs

The KES algorithm calculates the following compression property values and displays them on the computer screen:

Linearity of Compression (LC).

For each sample, 5 measurements were obtained.

Tensile strength test method

The tensile strength test method used herein is performed to measure the compressive tensile strength of each of the side zones 26a, 26b and the perforated zone of the materials according to the present invention. Tensile strength is usually reported as the value of force in pounds-force (gram-force) at a given deformation.

1. If the nonwoven fabric to be tested forms part of a composite or absorbent article, freeze spraying must be used to thoroughly remove the nonwoven fabric.

2. The side zones of the nonwoven fabric are cut from the perforated zone using a paper cutter along the machine direction. On each side of the perforated area, approximately 1 mm of lateral area may remain after cutting. Three fragments (side zone 1, side zone 2 and perforated zone) are subjected to separate tests on the tensile frame.

3. The upper and lower grips must have a width greater than the width of the test samples. The upper grip is connected to a 100 N load cell, while the lower grip is connected to the base of the dynamometer.

4. TestWorks Version 4 software provided by MTS is used to monitor the displacement of the upper jaw and record the load and distance between the two jaws. Test settings:

Working length=76.2 mm

Slider speed=305 mm/min

Preliminary partial load = 25 gram-force

5. The test sample with the longitudinal direction oriented vertically is placed in the center of the lower grips.

6. The upper grip is initiated to pull upward at a speed of 305 mm/min. The distance the upper gripper moves is indicated by reading the slider.

7. The tensile load and the corresponding distance that the upper grip moves during the test are recorded on a computer using TestWorks Version 4 software provided by MTS.

8. The travel length of the upper gripper is converted to relative deformation by dividing the travel length by the working length and multiplying by 100.

After recording this data, the tensile strength factor can be calculated. The tensile strength coefficient is determined as follows. If the results of the tensile strength test method are available for each of the side zones 1 and 2 and the perforated zone 16, find the deformation common to each of the samples of the side zone 1, the side zone 2 and the perforated zone, at which the total load (the load of the side zone 1 at total deflection + side zone 2 load at total deflection + perforated zone load at total deformation) is 1.2 lbf (544.3 grams-f). If there is no total deformation for which the combined load is 1.2 lbf, select a total deformation for which the combined load is as close as possible to 1.2 lbf. However, the combined load should still be within +/-10% of 1.2 lbf. After finding this total strain value, the tensile strength factor can be determined according to equation (1) below.

Coefficient = (load on side zone 1 with total deformation + load on side zone 2 with total deformation)

/ (load on the perforated area with general deformation) (1)

Test method for determining Poisson's ratio

The Poisson's ratio test method can be used to determine the amount of reduction in cross-section that a material may experience under longitudinal tension. Specifically, Poisson's ratio is a measure of the transverse strain of a material divided by the longitudinal strain. Herein, Poisson's ratios are reported as a ratio at a given longitudinal strain.

The steps of the test method for determining Poisson's ratio begin in the same way as steps 1-5 of the tensile strength test method, in which the sample is a perforated area of a sample of material. The following steps are specific to the test method for determining Poisson's ratio:

6. The width of the perforated area of the sample is marked as the midpoint of the material sample between the upper and lower grips with a felt-tip pen or other marking device, and the width of the material sample is measured along the marked section and recorded.

7. Initiate upward tension of the upper grip at a speed of 305 mm/min until 1% longitudinal deformation of the material sample is achieved. When the longitudinal deformation reaches 1%, the upper grip is stopped.

8. The width of the material sample is measured along the marked section and recorded.

9. Steps 7 and 8 are repeated for longitudinal strains of 2%, 3%, 4% and 5%.

10. The transverse strain values for the material sample are calculated for each of the achieved longitudinal strain values.

11. Poisson's ratio is then determined for the material sample at each recorded longitudinal strain value by dividing the determined transverse strain values by their corresponding longitudinal strain values.

Test method for determining the anisotropy of jumpers

The anisotropy of the fibers in the bond bridges 14 extending between longitudinally adjacent nodes 12 and the bond bridges 14 extending between transversely adjacent nodes 12 can be determined using the image analysis measurement method described herein.

In this context, fiber anisotropy is considered for a plurality of connecting bridges 14 within the perforated material zone 16 for each respective material. Typically, in the image analysis method, a numerical anisotropy value is determined from approximately eight (coronal) images of the connecting bridge 14 using a special image analysis measurement parameter called anisotropy. The anisotropy of the connecting bridge 14 can be measured using X-ray computed microtomography (also known as micro-CT) for non-destructive imaging, followed by image analysis techniques to identify fiber components, and then measuring the anisotropy of said components only in the areas of the connecting bridge 14. Image Analysis Algorithm performs detection, image processing and measurement, and transmits data digitally to a spreadsheet database. The resulting measurement data is used to compare the anisotropy of the connecting bridges 14 extending between nodes 12 adjacent in the longitudinal direction and the connecting jumpers 14 passing between nodes 12 adjacent in the transverse direction.

The method for determining anisotropy in the fibers of each of the connecting bridges includes the first stage of obtaining digital images of X-ray computed microtomography of the sample. These images are acquired using a SkyScan 1272 computed microtomography system available from Bruker microCT (2550 Contih, Belgium). The sample is attached to the mounting device provided by Bruker with the SkyScan 1272 system so that it does not move under its own weight during the scanning process. During the scanning process, the following SkyScan 1272 conditions are used:

Camera pixel size (µm)=9.0

- Source voltage (kV)=35

- Source current (µA)=225

- Image pixel size (µm)=6.0

- Image format=TIFF

- Depth (bits)=16

- Rotation step (degrees) = 0.10

- Use 360 rotation=NO

- Frame averaging=ENABLED (6)

- Random movement=ON (1)

- Correction for uniform field illumination=ON

- Filter=No filter

Once scanning of the sample is completed, the resulting set of images is then reconstructed using the NRecon program provided with the SkyScan 1272 CT microtomography system. Although reconstruction parameters may be somewhat sample dependent and should be known to one skilled in the art, the following parameters should provide basic guidelines for analyzing specialist:

- Image file type=BMP

- Pixel size (µm)=6.00

- Smoothing=1 (Gaussian)

- Correction of artifacts “ringing”=10

- Beam tightening correction (%)=10

Once reconstruction is complete, the resulting image dataset is ready for cross-sectional image slice extraction using the Bruker SkyScan software package called DataViewer (v. 1.5.6.3). After loading the entire dataset of reconstructed images into the DataViewer, the CT microtomography analyst must then select and extract cross-sectional (coronal) image slices at eight different locations along each junction 14 of interest. In a typical method, six different junctions 14 of each type are analyzed ( for example, connecting jumpers 14 extending between nodes 12 adjacent in the longitudinal direction, and connecting jumpers 14 passing between nodes 12 adjacent in the transverse direction). Once cross-sectional CT microtomography images have been obtained for each desired connecting bridge 14, anisotropy measurements can be made using image analysis software.

The image analysis software platform used to perform anisotropy measurements is QWIN Pro (version 3.5.1), available from Leica Microsystems, Heerbrugg, Switzerland.

Thus, a method for determining the anisotropy of a given sample includes the step of performing multiple anisotropy measurements on a set of computed microtomography images. More specifically, an image analysis algorithm is used to read and process images and perform measurements using the Quantimet Interactive Programming User System (QUIPS) language. The image analysis algorithm is reproduced below.

OPENING DATA FILES AND SETTING VARIABLES

The following lines indicate the location on the computer where the data is sent

Open File ( C:\Data\103470 - Nhan\data.xls, channel #1 )

ACQOUTPUT = 0

INSTALLATION AND CALIBRATION

Configure (Image Store 1504 x 1250, Gray Images 102, Binaries 32)

-- Pixel calibration value = 6.00 um/px

CALVALUE = 6.00

Calibration (Local)

Image frame ( x 0, y 0, Width 1504, Height 1250 )

Measure frame ( x 31, y 61, Width 1442, Height 1188 )

Enter Results Header

File Results Header ( channel #1 )

File Line ( channel #1 )

File Line ( channel #1 )

--Enter image file information

PauseText("Enter image file prefix name.")

Input ( TITLE$ )

Clear Feature Histogram #1

Clear Feature Histogram #2

Clear Field Histogram #1

FIELD/ANALYSIS LOOP

For (FIELD = 440 to 480, step 5)

IMAGE ACQUISITION AND DETECTION

-- Image File location

ACQFILE$ = "C:\Images\103470 - Nhan\Coronal Images\Rep #3\"+TITLE$+""+STR$(FIELD)+".jpg"

Read image ( from file ACQFILE$ into ACQOUTPUT )

FIBER IDENTIFICATION

Clear Feature Histogram #1

Clear Feature Histogram #2

Detect ( whiter than 55, from Image0 into Binary0 delineated )

IMAGE PROCESSING

Binary Amend ( Close from Binary0 to Binary1, cycles 1, operator Disc, edge erode on )

Binary Amend ( White Exh. Skeleton from Binary1 to Binary2, cycles 1, operator Disc, edge erode on, alg. 'L' Type )

Binary Identify ( Remove White Triples from Binary2 to Binary3 )

Display ( Image0 (on), frames (on,on), planes (off,off,off,3,off,off), lut 0, x 0, y 0, z 1, Reduction off )

ANISOTROPY OF THE MEASUREMENT FIELD

PauseText("Set measure frame region now.")

Measure frame [PAUSE] ( x 1296, y 255, Width 506, Height 497 )

MFLDIMAGE = 3

Measure field ( plane MFLDIMAGE, into FLDRESULTS(1), statistics into FLDSTATS(7,1) )

Selected parameters: Anisotropy

ANISOT = FLDRESULTS(1)

ORIENTATION OF MEASUREMENT ELEMENTS

Clear Accepts

Measure feature ( plane Binary3, 64 ferets, minimum area: 10, gray image: Image0 )

Selected parameters: X FCP, Y FCP, VertProj, HorizProj, Length,

Perimeter, UserDef1, UserDef2, DerivOrient

Feature Expression ( UserDef1 ( all features ), title Orient = PHPROJ(FTR)/PVPROJ(FTR) )

Feature Expression ( UserDef2 ( all features ), title Length = PPERIMETER(FTR)/2 )

Feature Histogram #1 ( Y Param UserDef2, X Param DerivOrient, from 0. to 180., linear, 20 bins )

Feature Histogram #2 ( Y Param UserDef2, X Param UserDef1, from 1.999999955e-002 to 200., logarithmic, 20 bins )

Display Feature Histogram Results ( #1, horizontal, differential, bins + graph (Y axis linear), statistics )

Data Window (1336, 117, 341, 454)

Display Feature Histogram Results ( #2, horizontal, differential, bins + graph (Y axis linear), statistics )

Data Window (1329, 566, 341, 454)

-- Output data to spreadsheet

File Feature Histogram Results ( #1, differential, statistics, bin details, channel #1 )

File Line ( channel #1 )

File Line ( channel #1 )

File Feature Histogram Results ( #2, differential, statistics, bin details, channel #1 )

File Line ( channel #1 )

File Line ( channel #1 )

File("Anisotropy=", channel #1)

File ( ANISOT, channel #1, 3 digits after '.' )

File Line ( channel #1 )

File Line ( channel #1 )

File Line ( channel #1 )

Next (FIELD)

Close File ( channel #1 )

The QUIPS algorithm is performed using the QWIN Pro software platform. First, the analyzer is prompted to enter the number of images in the set for a particular sample. The analyzer is then prompted to enter a set of sample identification information, which is sent to an EXCEL file.

The analyzer is then prompted through an interactive command window and input window to enter the image file prefix of the CT microtomography images being analyzed. After this step, all subsequent images for a given sample will be automatically read by the image analysis algorithm described above.

The analyzer is then provided with prompts to manually select, using a computer mouse, the jumper region of interest for analysis. Care must be taken to select only the jumper of interest.

After several stages of image processing, which will occur automatically, the analyzer will again be prompted to clean up any areas that extend beyond the region of interest (ROI). This is done by using the computer mouse, and by enabling and disabling the binary overlay by simultaneously using the "control" and "b" keys on the computer keyboard. After this step, the binary image should only cover the connecting jumper.

The process of selecting an area of interest on the jumper 14 and clearing areas beyond it will be repeated until all images for a particular sample have been analyzed.

Once all images have been analyzed, the following measurement parameter data will be located in the corresponding EXCEL file:

Copy number

Anisotropy

For Anisotropy, 6 values will be listed in the columns. In order to compare the anisotropy values between the connecting bridges 14 that connect the nodes 12 adjacent in the longitudinal direction and the connecting jumpers 14 that connect the nodes 12 adjacent in the transverse direction, the data in the column labeled "Anisotropy" is compared between different samples by performing Student's T-analysis with 90% confidence level.

Embodiments

Embodiment 1. In the first embodiment, the nonwoven fabric may comprise a plurality of fibers and may extend between a first end and a second end, wherein the nonwoven fabric has a material width and may further comprise a first surface and a second surface, wherein the first surface is on an opposite side relative to of a second surface, a perforated area comprising a plurality of nodes extending from a reference plane on the first surface, a plurality of connecting links connecting the plurality of nodes to each other, wherein the majority of the plurality of nodes comprises at least three connecting links connected to adjacent nodes, and a plurality of holes providing the perforated area of the nonwoven fabric with a percentage open area that is greater than about 15%, as determined by a test method based on analysis of a sample of the material; a first side zone and a second side zone, wherein the first side zone has the width of the first side zone and the second side zone has the width of the second side zone, and wherein each of the width of the first side zone and the width of the second side zone can be from about 5% to about 25% of the width of the non-woven fabric.

Embodiment 2 In the second embodiment, each of the width of the first side region and the width of the second side region according to Embodiment 1 may be from about 5% to about 15% of the width of the nonwoven material.

Embodiment 3 In the third embodiment, the width value of the first side region according to any of Embodiments 1 or 2 may be within approximately 25% of the width value of the second side region.

Embodiment 4 In a fourth embodiment, the plurality of holes according to any one of Embodiments 1 to 3 can provide an open area percentage for the perforated area of the nonwoven fabric that is more than about 20% as determined by a test method based on analysis of a material sample.

Embodiment 5: In a fifth embodiment, each of the first side region and the second side region according to any of embodiments 1 to 4 may have a percentage open area that is greater than about 0.5% and less than about 10%, as determined by the test method for based on analysis of a material sample.

Embodiment 6 In the sixth embodiment, the perforated area according to any of Embodiments 1 to 5 may have a Poisson's ratio of less than about 3 at a strain of 1% as determined by the Poisson's ratio test method.

Embodiment 7 In the seventh embodiment, each of the first side region and the second side region according to any of embodiments 1 to 6 may extend between the first end of the nonwoven material and the second end of the nonwoven material.

Embodiment 8: In an eighth embodiment, the nonwoven fabric may comprise a plurality of fibers and may extend between the first end and the second end, and may further comprise a perforated area, wherein the perforated area comprises a plurality of holes providing the perforated area of the nonwoven material with an open area percentage, which is more than about 15%, as determined by a test method based on analysis of a sample of the material; and a first side zone and a second side zone, wherein each of the first side zone and the second side zone has a percentage open area that is greater than about 0.5% and less than the percentage open area of the perforated zone, as determined by the test method based on sample analysis material, wherein the ratio equal to the sum of the tensile strength of the first side zone and the tensile strength of the second side zone divided by the tensile strength of the perforated zone can be from about 0.8 to about 2.5.

Embodiment 9 In the ninth embodiment, the ratio equal to the sum of the tensile strength of the first side zone and the second side zone divided by the perforated zone according to Embodiment 8 may be from about 0.8 to about 1.75.

Embodiment 10 In the tenth embodiment, the perforated area according to any one of embodiments 8 or 9 may further comprise a plurality of nodes extending from the reference plane on the first surface, and a plurality of connecting bridges connecting the plurality of nodes to each other, wherein most of the plurality of nodes may contain at least three connecting jumpers connected to adjacent nodes.

Embodiment 11 In the eleventh embodiment, each connecting jumper according to embodiment 10 can only extend between two adjacent nodes.

Embodiment 12 In a twelfth embodiment, the plurality of holes according to any one of embodiments 8 to 11 can provide an open area percentage for the perforated area of the nonwoven material that is more than about 20% as determined by a test method based on analysis of a material sample.

Embodiment 13 In the thirteenth embodiment, the nonwoven fabric according to any of Embodiments 8 to 12 may have a material width, and the first side zone has the width of the first side zone, and the second side zone has the width of the second side zone, each of the width of the first side zone zone and the width of the second side zone can be from about 5% to about 25% of the width of the nonwoven material.

Embodiment 14 In the fourteenth embodiment, the first side region and the second side region according to any of embodiments 8 to 13 may have a width of the first side region and a width of the second side region, and the amount of the width of the first side region may be within approximately 50% of the value the width of the second side zone.

Embodiment 15: In a fifteenth embodiment, the nonwoven fabric may comprise a plurality of fibers and may extend between the first end and the second end, and may further comprise a perforated zone, wherein the perforated zone comprises a plurality of holes providing the perforated zone of the nonwoven fabric with a percentage open area, which is more than about 15%, as determined by a test method based on analysis of a sample of the material; and a first side zone and a second side zone, wherein each of the first side zone and the second side zone has a percentage open area that is greater than about 0.5% and less than the percentage open area of the perforated zone, as determined by the test method based on sample analysis material, wherein the Poisson's ratio of the perforated zone of the nonwoven material is less than about 3 at a strain of 1%, as determined by a test method for determining Poisson's ratio.

Embodiment 16 In the sixteenth embodiment, the Poisson's ratio of the perforated region of the nonwoven fabric according to Embodiment 15 can be less than about 2 at a strain of 1% as determined according to the test method for determining the Poisson's ratio.

Embodiment 17 In a seventeenth embodiment, the perforated area according to any one of embodiments 15 or 16 may further comprise a plurality of nodes extending from the reference plane on the first surface, and a plurality of connecting bridges connecting the plurality of nodes to each other, wherein most of the plurality of nodes contain at least three connecting jumpers connected to adjacent nodes.

Embodiment 18 Meanwhile, in the eighteenth embodiment, each connecting bridge according to Embodiment 17 can only extend between two adjacent nodes.

Embodiment 19 In a nineteenth embodiment, the plurality of holes according to any one of embodiments 15 to 18 can provide an open area percentage for the perforated area of the nonwoven fabric that is more than about 20% as determined by a test method based on analysis of a material sample.

Embodiment 20 In the twentieth embodiment, the nonwoven fabric according to any of embodiments 15 to 19 may have a material width, and the first side region may have the width of the first side region, and the second side region may have the width of the second side region, each of the width the first side zone and the width of the second side zone can be from about 5% to about 25% of the width of the nonwoven material.

All documents referred to in the detailed description are incorporated herein by reference to the relevant extent, and mention of any document should not be construed as an admission that it is prior art with respect to the present invention. If any meaning or definition of a term in this written document conflicts with any meaning or definition of a term in a document incorporated by reference, then the meaning or definition with which the term is used in that written document shall control.

While specific embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications may be made without departing from the spirit and scope of the present invention. It is therefore intended that the appended claims cover all changes and modifications that fall within the scope of the present invention.

Claims (33)

1. A nonwoven fabric comprising a plurality of fibers and extending between a first end and a second end, the nonwoven fabric having a material width and comprising: a first surface and a second surface, the first surface being opposite the second surface; a perforated zone, wherein the perforated zone contains: a set of nodes extending from the base plane on the first surface, a plurality of connecting jumpers connecting the plurality of nodes to each other, wherein the majority of the plurality of nodes comprises at least three connecting jumpers connected to adjacent nodes, and a plurality of holes providing a percentage open area for the perforated area of the nonwoven material that is greater than about 15%, as determined by a test method based on analysis of a sample of the material; And a first side zone and a second side zone, wherein the first side zone has the width of the first side zone, and the second side zone has the width of the second side zone, and wherein each of the width of the first side zone and the width of the second side zone is from about 5% to about 25% of the width of the nonwoven material. 2. The nonwoven fabric of claim 1, wherein each of the width of the first side zone and the width of the second side zone is from about 5% to about 15% of the width of the nonwoven fabric. 3. Nonwoven material according to claim 1, characterized in that the width of the first side zone is within approximately 25% of the width of the second side zone. 4. The nonwoven fabric of claim 1, wherein the plurality of holes provide a percentage open area for the perforated area of the nonwoven fabric that is greater than about 20% as determined by a test method based on analysis of a sample of the material. 5. The nonwoven fabric of claim 1, wherein each of the first side zone and the second side zone has an open area percentage that is greater than about 0.5% and less than about 10%, as determined by a test method based on analysis of a sample of the material . 6. The nonwoven fabric according to claim 1, wherein the Poisson's ratio of the perforated zone of the nonwoven fabric is less than about 3 at a strain of 1%, as determined by a test method for determining Poisson's ratio. 7. The nonwoven fabric of claim 1, wherein each of the first side zone and the second side zone extends between the first end of the nonwoven fabric and the second end of the nonwoven fabric. 8. A nonwoven material comprising a plurality of fibers and extending between a first end and a second end, the nonwoven material comprising: a perforated zone, wherein the perforated zone contains a plurality of holes providing a percentage open area for the perforated zone of the nonwoven material that is greater than about 15%, as determined by a test method based on analysis of a sample of the material; And a first side zone and a second side zone, wherein each of the first side zone and the second side zone has a percentage open area that is greater than about 0.5% and less than the percentage open area of the perforated zone, as determined by a test method based on analysis of a sample of the material , wherein the ratio equal to the sum of the tensile strength of the first side zone and the tensile strength of the second side zone divided by the tensile strength of the perforated zone is from about 0.8 to about 2.5. 9. The nonwoven fabric of claim 8, wherein the ratio equal to the sum of the tensile strength of the first side zone and the second side zone divided by the perforated zone is from about 0.8 to about 1.75. 10. The nonwoven fabric according to claim 8, characterized in that the perforated zone further comprises a plurality of nodes extending from the base plane on the first surface, and a plurality of connecting bridges connecting the plurality of nodes to each other, wherein a majority of the plurality of nodes contains at least at least three connecting jumpers connected to adjacent nodes. 11. Non-woven material according to claim 10, characterized in that each connecting bridge passes only between two adjacent nodes. 12. The nonwoven fabric of claim 8, wherein the plurality of holes provide a percentage open area for the perforated area of the nonwoven fabric that is greater than about 20%, as determined by a test method based on analysis of a sample of the material. 13. The nonwoven material according to claim 8, wherein the nonwoven material has a material width, and the first side zone has the width of the first side zone, and the second side zone has the width of the second side zone, and each of the width of the first side zone and the width of the second the side zone is from about 5% to about 25% of the width of the nonwoven material. 14. Nonwoven fabric according to claim 8, characterized in that the first side zone has the width of the first side zone and the second side zone has the width of the second side zone, and the width of the first side zone is within approximately 50% of the width of the second side zone . 15. A nonwoven material comprising a plurality of fibers and extending between a first end and a second end, the nonwoven material comprising: a perforated zone, wherein the perforated zone contains a plurality of holes providing a percentage open area for the perforated zone of the nonwoven material that is greater than about 15%, as determined by a test method based on analysis of a sample of the material; And a first side zone and a second side zone, wherein each of the first side zone and the second side zone has a percentage open area that is greater than about 0.5% and less than the percentage open area of the perforated zone, as determined by a test method based on analysis of a sample of the material , wherein the Poisson's ratio of the perforated zone of the nonwoven material is less than about 3 at a strain of 1% as determined by the Poisson's ratio test method. 16. The nonwoven fabric of claim 15, wherein the Poisson's ratio of the perforated zone of the nonwoven fabric is less than about 2 at a strain of 1% as determined by the Poisson's ratio test method. 17. The nonwoven fabric of claim 15, wherein the perforated zone further comprises a plurality of nodes extending from the base plane on the first surface, and a plurality of connecting bridges connecting the plurality of nodes to each other, wherein a majority of the plurality of nodes comprises at least at least three connecting jumpers connected to adjacent nodes. 18. Non-woven material according to claim 17, characterized in that each connecting bridge passes only between two adjacent nodes. 19. The nonwoven fabric of claim 15, wherein the plurality of holes provide a percentage open area for the perforated area of the nonwoven fabric that is greater than about 20%, as determined by a test method based on analysis of a sample of the material. 20. The nonwoven fabric of claim 15, wherein the nonwoven fabric has a material width, and the first side zone has the width of the first side zone, and the second side zone has the width of the second side zone, and each of the width of the first side zone and the width of the second the side zone is from about 5% to about 25% of the width of the nonwoven material.