Shaped nonwoven

Patent metadata

Field	Value
Publication number	US-11634838-B2
Application number	US-202117475642-A
Country	US
Kind code	B2
Filing date	Sep 15, 2021
Priority date	Jun 30, 2017
Publication date	Apr 25, 2023
Grant date	Apr 25, 2023

Abstract

A nonwoven fabric. The nonwoven fabric can include a first surface and a second surface and a visually discernible pattern of three-dimensional features on one of the first or second surface. Each of the three-dimensional features can define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property. The nonwoven further has a plurality of apertures, wherein at least a portion of the aperture abuts at least one of the first region and the second region of the microzone.

First claim

What is claimed is:

1. A nonwoven fabric comprising a first surface, a second surface, and at least first and second visually discernible zones on one of the first or second surface, each of the first and second zones having a visually different pattern of three-dimensional features that each comprise at least two distinct three-dimensional features, each of the patterns of three-dimensional features defining a microzone comprising a first region and a second region that correspond to the at least two distinct three-dimensional features, wherein the difference in values for an intensive property for the first region and the second region of the microzone in the first zone is different than the difference in values for the intensive property for the first region and the second region of the microzone in the second zone, wherein the intensive property is one or more of:
a. thickness,
b. basis weight,
c. volumetric density;
wherein the first surface has a first TS7 value, wherein the second surface has a second TS7 value, and wherein the first TS7 value is different than the second TS7 value; and
wherein at least a portion of one or more of the three-dimensional features forms a curvilinear shape.

2. The nonwoven fabric of claim 1 , wherein the first TS7 value is in the range of about 3 to about 14 dB V2 rms.

3. The nonwoven fabric of claim 1 , wherein the second TS7 value is in the range of about 2 dB V2 rms to about 12 dB V2 rms.

4. The nonwoven fabric of claim 1 , wherein the intensive property is thickness, and wherein the difference in thickness between the first and second regions in the first zone or the second zone is greater than 25 microns.

5. The nonwoven fabric of claim 1 , wherein the intensive property is basis weight, and wherein the difference in basis weight between the first and second regions in the first zone or the second zone is greater than 5 gsm.

6. The nonwoven fabric of claim 1 , wherein the intensive property is volumetric density, and wherein the difference in volumetric density between the first and second regions in the first zone or the second zone is greater than 0.042 g/cc.

7. The nonwoven fabric of claim 1 , wherein a plurality of the microzones of the nonwoven fabric comprise an aperture, wherein at least a portion of the aperture abuts at least one of the first region and the second region in the first zone or the second zone, and wherein loose fibers extend into the aperture.

8. The nonwoven fabric of claim 7 , wherein the loose fibers extending into the aperture originate in at least one of the abutting first or second regions in the first zone or the second zone.

9. A nonwoven fabric comprising:
a first surface a second surface, and at least first and second visually discernible zones on at least one of the first and second surface, each of the first and second zones having a different pattern of three-dimensional features that each comprise at least two distinct three-dimensional features, each of the patterns of three-dimensional features defining a microzone comprising a first region and a second region that correspond to the at least two distinct three-dimensional features, the first and second regions having a difference in values for an intensive property;
wherein the difference in values for an intensive property for the first region and the second region of the microzone in the first zone is different from the difference in values for the intensive property for the first region and the second region of the microzone in the second zone;
wherein the first surface has a first TS7 value, wherein the second surface has a second TS7 value, and wherein the first TS7 value is different than the second TS7 value; and
wherein at least a portion of one or more of the three-dimensional features forms a curvilinear shape.

10. The nonwoven fabric of claim 9 , wherein the difference in values for the intensive property for the first region and the second region of the microzone in the first zone is an order of magnitude different from the difference in values for the intensive property for the first region and the second region of the microzone in the second zone.

11. The nonwoven fabric of claim 9 , wherein the intensive property is thickness, and wherein the thickness of every region is greater than zero.

12. The nonwoven fabric of claim 9 , wherein the intensive property is basis weight, and wherein the basis weight of every region is greater than zero.

13. The nonwoven fabric of claim 9 , wherein the intensive property is volumetric density, and wherein the volumetric density of every region is greater than zero.

14. The nonwoven fabric of claim 9 , wherein a plurality of the microzones within at least one of the first or second visually discernible zones comprise an aperture, wherein at least a portion of the aperture abuts at least one of the first region and the second region in the first zone or the second zone, and wherein loose fibers extend into the aperture.

15. The nonwoven fabric of claim 14 , wherein the loose fibers extending into the aperture originate in at least one of the abutting first or second regions in the first zone or the second zone.

16. The nonwoven fabric of claim 9 , comprising a third zone having a pattern of three-dimensional features that each define a microzone comprising a first region and a second region.

17. The nonwoven fabric of claim 9 , wherein the first TS7 value is in the range of about 3 to about 14 dB V2 rms.

18. The nonwoven fabric of claim 9 , wherein the second TS7 value is in the range of about 2 dB V2 rms to about 12 dB V2 rms.

19. A nonwoven fabric comprising a first surface, a second surface, and at least first and second visually discernible zones on one of the first or second surface, each of the first and second zones having a visually different pattern of three-dimensional features that each comprise at least two distinct three-dimensional features, each of the patterns of three-dimensional features defining a microzone comprising a first region and a second region that correspond to the at least two distinct three-dimensional features, wherein the difference in values for an intensive property for the first region and the second region of the microzone in the first zone is different than the difference in values for the intensive property for the first region and the second region of the microzone in the second zone, wherein the intensive property is one or more of:
a. thickness,
b. basis weight,
c. volumetric density;
wherein the first surface has a first TS7 value of about 3 to about 14 dB V2 rms,
wherein the second surface has a second TS7 value in the range of about 2 dB V2 rms to about 12 dB V2 rms, and wherein the first TS7 value is different than the second TS7 value; and
wherein at least a portion of one or more of the three-dimensional features forms a curvilinear shape.

20. The nonwoven fabric of claim 19 , wherein the intensive property is basis weight, and wherein the basis weight of every region is greater than zero.

Assignees

• Procter & Gamble

Inventors

• Ashraf Arman
• Arora Kelyn Anne
• Weisman Paul Thomas
• Whitely Nathan Ray

Classifications

• A61F2013/49092

  comprising leg cuffs · CPC title

• A61F13/55115

  characterized by the features before use, e.g. how are the diapers folded or arranged in a package · CPC title

• A61F13/15252

  compostable or biodegradable · CPC title

• A61F2013/15373

  Calliper, i.e. thickness · CPC title

• A61F13/15658

  Forming continuous, e.g. composite, fibrous webs, e.g. involving the application of pulverulent material on parts thereof · CPC title