Method for making a shaped nonwoven

Patent metadata

Field	Value
Publication number	US-11746441-B2
Application number	US-202117361370-A
Country	US
Kind code	B2
Filing date	Jun 29, 2021
Priority date	Jun 30, 2017
Publication date	Sep 5, 2023
Grant date	Sep 5, 2023

Abstract

A method for making nonwoven fabric. The nonwoven fabric can include three-dimensional features that 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 two different, visually discernible patterns on at least one of the first and second surfaces, the at least two different, visually discernible patterns each having a regular, repeating pattern of three-dimensional features, each of the three-dimensional features defining a microzone comprising a first region and a second region, the first and second regions having a difference in values for an intensive property;
wherein the intensive property is basis weight or volumetric density;
wherein the first surface has a TS7 value in the range of about 1 dB V 2 rms to about 15 dB V 2 rms;
wherein the second surface has a TS7 value in the range of about dB V 2 rms to about 15 dB V 2 rms;
wherein the TS7 value of the first surface is different than the TS7 value of the second surface;
wherein the nonwoven fabric is air through bonded;
wherein the nonwoven fabric retains greater than 70% of its original average caliper after being tested by the Compression Aging Test at a pressure of 35 KPa; and
wherein the nonwoven fabric comprises bicomponent fibers.

2. The nonwoven fabric of claim 1 , wherein a ratio of the TS7 value of the first surface to the TS7 value of the second surface is in the range of about 1 to about 3.

3. The nonwoven fabric of claim 1 , wherein the bicomponent fibers comprise a side-by-side arrangement.

4. The nonwoven fabric of claim 1 , wherein the bicomponent fibers comprise a sheath core arrangement.

5. The nonwoven fabric of claim 4 , wherein the sheath comprises polyethylene, and wherein the core comprises polypropylene.

6. The nonwoven fabric of claim 5 , wherein a ratio of a weight f the sheath to a weight of the core is from about 5:95 to about 95:5.

7. The nonwoven fabric of claim 1 , comprising inorganic filters.

8. The nonwoven fabric of claim 1 , comprising a slip additive.

9. The nonwoven fabric of claim 1 , wherein the bicomponents fibers are spunbond fibers.

10. The nonwoven fabric of claim 1 , wherein the first region has a different thickness and opacity as the second region.

11. The nonwoven fabric of claim 1 , wherein the intensive property is basis weight.

12. The nonwoven fabric of claim 1 , wherein the intensive property is volumetric density.

13. The nonwoven fabric of claim 1 , wherein an average basis weight is between about 5 gsm and about 30 gsm.

14. An absorbent article comprising:
the nonwoven fabric of claim 1 .

15. The absorbent article of claim 14 , comprising a topsheet comprising the nonwoven fabric.

16. The absorbent article of claim 14 , comprising a backsheet nonwoven comprising the nonwoven fabric.

17. The absorbent article of claim 14 , comprising an absorbent core comprising an absorbent material, wherein a channel is defined in the absorbent material, and wherein the channel is substantially free of the absorbent material.

18. The absorbent article of claim 14 , comprising an elastic waist feature.

19. A package comprising a plurality of the absorbent articles of claim 14 , wherein the package has an in-bag stack height of between about 70 mm and about 100 mm, according to the In-Bag Stack Height Test.

20. A nonwoven fabric comprising:
a first surface;
a second surface; and
at least two different, visually discernible patterns on at least one of the first and second surfaces, the at least two different, visually discernible patterns each having a regular, repeating pattern of three-dimensional features, each of the three-dimensional features defining a microzone comprising a first region and a second region, the first and second regions having a difference in values for an intensive property;
wherein the intensive property is basis weight;
wherein the first surface has a TS7 value in the range of about 1 dB V 2 rms to about 15 dB V 2 rms;
wherein the second surface has a TS7 value in the range of about 1 dB V 2 rms to about 15 dB V 2 rms;
wherein the TS7 value of the first surface is different than the TS7 value of the second surface;
wherein the nonwoven fabric is air through bonded;
wherein the nonwoven fabric retains greater than 70% of its original average caliper after being tested by the Compression Aging Test at a pressure of 35 KPa; and
wherein the nonwoven fabric comprises bicomponent fibers.

Assignees

• Procter & Gamble

Inventors

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

Classifications

• D01D5/0985 Primary

  by means of a flowing gas (e.g. melt-blowing) · CPC title

• A61F13/15252

  compostable or biodegradable · CPC title

• A61F13/15658

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

• A61F13/4902

  characterised by the elastic material · CPC title

• A61F13/51104

  the top sheet having a three-dimensional cross-section, e.g. corrugations, embossments, recesses or projections · CPC title