Absorbent article with function-formed topsheet, and method for manufacturing

Patent metadata

Field	Value
Publication number	US-12324732-B2
Application number	US-202318487172-A
Country	US
Kind code	B2
Filing date	Oct 16, 2023
Priority date	Jun 19, 2019
Publication date	Jun 10, 2025
Grant date	Jun 10, 2025

Abstract

An absorbent article is disclosed. The article includes a topsheet formed of a section of formed nonwoven web material having an ordered arrangement of zones, each zone comprising one or more attenuated regions adjacent to one or more built-up regions, wherein the attenuated regions have a first average basis weight and the built-up regions have a second average basis weight, wherein the first average basis weight is less than the second average basis weight, the difference in basis weights corresponding to disposition of the filaments according to the ordered arrangement. The attenuated region(s) may include a plurality of discrete low bulk portions arranged in a pattern disposed along a longitudinal axis of the article, which facilitate z-direction movement of fluid through the topsheet and inhibit spreading of a fluid stain along the topsheet in the x and y directions.

First claim

What is claimed is:

1. An absorbent article comprising a liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent structure disposed between the topsheet and the backsheet, the topsheet having a central lateral axis, a longitudinal axis and an in-use wearer-facing portion having an elongate outer perimeter,
wherein the topsheet is formed of a section of formed nonwoven web material comprising an accumulation of filaments and having an absorbent-facing side and a wearer-facing side, the wearer-facing side comprising an ordered arrangement of zones, each zone comprising one or more attenuated regions adjacent to one or more built-up regions,
wherein the attenuated regions have a first average basis weight and the built-up regions have a second average basis weight, wherein the first average basis weight is less than the second average basis weight, the difference in basis weight corresponding to disposition of the filaments according to the ordered arrangement;
wherein the attenuated regions comprise a plurality of discrete low bulk portions arranged in a pattern disposed in a direction generally along the longitudinal axis;
wherein the attenuated regions comprise a configuration of one or more channel portions predominately circumscribing a discharge locus on the longitudinal axis; and
wherein the one or more channel portions are centered about the discharge locus, and wherein the one or more channel portions extend a full length of the topsheet.

2. The absorbent article of claim 1 , wherein the attenuated region(s) and built-up region(s) are visually discernible.

3. The absorbent article of claim 1 , wherein the discrete low bulk portions occupy 5 percent to 30 percent of a total area occupied by the pattern.

4. The absorbent article of claim 1 , wherein the topsheet has a surfactant applied to the absorbent-facing side such that the surfactant is present in a quantity greater on filaments proximate the absorbent-facing side than on filaments proximate the wearer-facing side.

5. The absorbent article of claim 4 , wherein a melt additive comprising a compound selected from the group consisting of erucamide, stearamide, oleamide, silicones, petroleum-based hydrocarbons having from about 4 to about 32 carbon atoms, fatty alcohols having from about 12 to about 24 carbon atoms, polysiloxane compounds, fatty acid esters, alkyl ethoxylates, fatty alcohol ethers having from about 12 to about 28 carbon atoms in their fatty chain, lanolin and its derivatives, glyceride derivatives including acetoglycerides and ethoxylated glycerides of C12-C28 fatty acids, fatty amides, and combinations thereof has been added to polymeric resin(s) from which the filaments have been spun.

6. The absorbent article of claim 1 , wherein the second average basis weight differs from the first average basis weight by at least a factor of 2.

7. The absorbent article of claim 1 , wherein the filaments are spun bicomponent filaments.

8. An absorbent article in the form of a feminine hygiene pad, comprising a liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent structure disposed between the topsheet and the backsheet, the topsheet having a central lateral axis, a longitudinal axis and an in-use wearer-facing portion having an elongate outer perimeter,
wherein the topsheet is formed of a section of formed nonwoven web material comprising an accumulation of filaments and having an absorbent-facing side and a wearer-facing side, the wearer-facing side comprising an ordered arrangement of zones, each zone comprising one or more attenuated regions adjacent to one or more built-up regions,
wherein the attenuated regions have a first average basis weight and the built-up regions have a second average basis weight, wherein the first average basis weight is less than the second average basis weight, the difference in basis weight corresponding to disposition of the filaments according to the ordered arrangement;
wherein the attenuated regions comprise a plurality of discrete low bulk portions arranged in a pattern disposed in a direction generally along the longitudinal axis;
wherein the article is configured to exhibit a Rewet of no greater than 0.50 g;
wherein the article is configured to exhibit an Acquisition Time of no greater than 25 seconds;
wherein the attenuated regions comprise a configuration of one or more channel portions predominately circumscribing a discharge locus on the longitudinal axis; and
wherein the one or more channel portions are centered about the discharge locus, and wherein the one or more channel portions extend a full length of the topsheet.

9. The absorbent article of claim 8 , exhibiting a Rewet of 0.24 g to no greater than 0.50 g.

10. The absorbent article of claim 9 , exhibiting an Acquisition Time of 4 seconds to no greater than 25 seconds.

11. The absorbent article of claim 8 , wherein the discrete low bulk portions occupy 5 percent to 30 percent of a total area occupied by the pattern.

12. An absorbent article comprising a liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent structure disposed between the topsheet and the backsheet, the topsheet having a central lateral axis, a longitudinal axis and an in-use wearer-facing portion having an elongate outer perimeter,
wherein the topsheet is formed of a section of formed nonwoven web material comprising an accumulation of filaments and having an absorbent-facing surface and a wearer-facing surface,
wherein the nonwoven web material has been formed via continuous deposition of spun filaments onto a forming belt having an outer receiving side and an inner side and moving along a machine direction through a working location, to form a batt of filaments deposited on the receiving side of the forming belt, the forming belt comprising an airflow permeable substrate belt and an ordered arrangement of airflow blocking structures disposed on the substrate belt, thereby imparting to the forming belt an ordered arrangement of airflow-permeable regions and airflow-blocked regions coextensive with the airflow blocking structures, the airflow blocking structures extending in a z-direction outward from the substrate belt so as to have a z-direction depth on the receiving side of the forming belt;
wherein before and as they contact the forming belt the filaments are entrained in air flow directed at and through the belt generally along the z-direction, such that the filaments accumulate on the forming belt to a greater second average basis weight over the airflow-permeable regions and to a lesser first average basis weight over the airflow- blocked regions, to create built-up regions of the batt over the airflow-permeable portions and attenuated regions of the batt over the airflow-blocked regions;
wherein the batt is consolidated into a nonwoven web material following its formation on the forming belt;
whereby the attenuated regions form a plurality of z-direction depressions predominately in the wearer-facing surface of the section of formed nonwoven web material, the plurality depressions defining a configuration of one or more channel portions following one or a plurality of paths, the one or plurality of paths being substantially symmetric about the longitudinal axis and predominately circumscribing a discharge locus on the longitudinal axis; and the plurality of depressions defining a pattern of discrete low bulk portions arranged in a direction generally along the longitudinal axis; and
wherein the one or more channel portions are centered about the discharge locus, and wherein the one or more channel portions extend a full length of the topsheet.

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Assignees

• Procter & Gamble

Inventors

• Arora Kelyn Anne
• Ashraf Arman
• Aviles Misael Omar
• Cruzmurphy Lennie
• Grenier Adrien
• Hammons John Lee
• Weisman Paul Thomas
• Whitely Nathan Ray

Classifications

• A61F13/15707

  Mechanical treatment, e.g. notching, twisting, compressing, shaping · CPC title

• D01F8/04

  from synthetic polymers · CPC title

• A61F2013/5113

  being foams · CPC title

• A61F13/512

  characterised by its apertures, e.g. perforations · CPC title

• A61F13/472

  specially adapted for female use · CPC title