Patterned apertured nonwoven

Patent metadata

Field	Value
Publication number	US-2024252369-A1
Application number	US-202418635141-A
Country	US
Kind code	A1
Filing date	Apr 15, 2024
Priority date	Oct 30, 2020
Publication date	Aug 1, 2024
Grant date	—

Abstract

The present disclosure relates to a nonwoven substrate comprising a plurality of apertures that form a pattern and define a plurality of discrete non-aperture zones. Each of the plurality of discrete non-aperture zones has a periphery formed by a continuous line of apertures, with adjacent apertures being spaced apart by an edge-to-edge distance of no more than 3 mm, while each of the plurality of discrete non-aperture zones is substantially free of apertures within the periphery. Particularly, the area ratio of such plurality of discrete non-aperture zones over the nonwoven substrate ranges from 60% to 90%, and at least some of said plurality of discrete non-aperture zones have an area of 100 mm2 or more.

First claim

What is claimed is:

1 . A nonwoven substrate comprising:
a) a top surface; b) a bottom surface; and c) a plurality of apertures, each of which extends from the top surface through said nonwoven substrate to the bottom surface,
wherein said plurality of apertures define a plurality of discrete non-aperture zones;
wherein each of said plurality of discrete non-aperture zones has a periphery formed by a continuous line of apertures; wherein each of said plurality of discrete non-aperture zones is substantially free of apertures within the periphery; wherein the area ratio of said plurality of discrete non-aperture zones over said nonwoven substrate ranges from 60% to 90%; and wherein some of said plurality of discrete non-aperture zones have an area of 100 mm 2 or more,
wherein each of said plurality of apertures has a size of greater than about 0.2 mm 2 , and
wherein said plurality of apertures further define one or more aperture zones;
wherein each of said one or more aperture zones comprises four or more apertures therein; wherein each aperture within each of said aperture zones has at least three adjacent apertures.

2 . The nonwoven substrate of claim 1 , wherein the area ratio of said plurality of discrete non-aperture zones over said nonwoven substrate ranges from 62% to 80%, or from 65% to 75%.

3 . The nonwoven substrate of claim 1 , wherein some of said plurality of discrete non-aperture zones have an area of 150 mm 2 or more, or 200 mm 2 or more, or 300 mm 2 or more.

4 . The nonwoven substrate of claim 1 wherein each of said plurality of apertures has a diameter ranging from 0.5 mm to 1.5 mm, or from 0.7 mm to 1.2 mm; and/or wherein said plurality of apertures have regular shapes selected from the group consisting of circle, oval, triangle, square, rectangle, parallelogram, trapezoid, polygon, hour-glass, star, and any combinations thereof.

5 . The nonwoven substrate of claim 1 , wherein each of said plurality of discrete non-aperture zones has an area of more than 6 mm 2 ; and/or wherein each of said plurality of discrete non-aperture has a minor dimension of more than 2.5 mm.

6 . The nonwoven substrate of claim 1 , wherein some of said plurality of discrete non-aperture zones have a major dimension of 15 mm or more, or 18 mm or more, or 20 mm or more.

7 . The nonwoven substrate of claim 6 , comprising a plurality of discrete aperture zones.

8 . The nonwoven substrate of claim 6 , comprising a continuous aperture zone.

9 . The nonwoven substrate of claim 1 , wherein the nonwoven substrate is a relofted nonwoven.

10 . The nonwoven substrate of claim 1 , wherein the nonwoven substrate has:
a compression work no less than about 700 gf×mm, as measured according to Compression Property Test; and/or a basis weight in the range of about 15 gsm to about 75 gsm.

11 . An absorbent article comprising a liquid pervious topsheet, a liquid impervious backsheet, an absorbent structure disposed between the topsheet and the backsheet, wherein the liquid pervious topsheet comprises the nonwoven substrate according to claim 1 .

12 . An absorbent article comprising a liquid pervious topsheet, a liquid impervious backsheet, an absorbent structure disposed between the topsheet and the backsheet, wherein the liquid impervious backsheet comprises the nonwoven substrate according to claim 1 .

13 . A method for manufacturing an apertured nonwoven substrate, comprising the steps of:
providing a nonwoven substrate having a top surface and a bottom surface; and forming a plurality of apertures that each extends from the top surface through said nonwoven substrate to the bottom surface, wherein said plurality of apertures define a plurality of discrete non-aperture zones; wherein each of said plurality of discrete non-aperture zones has a periphery formed by a continuous line of apertures; wherein each of said plurality of discrete non-aperture zones is substantially free of apertures within the periphery; wherein the area ratio of said plurality of discrete non-aperture zones over said nonwoven substrate ranges from 60% to 90%; and wherein some of said plurality of discrete non-aperture zones have an area of 100 mm 2 or more, wherein each of said plurality of apertures has a size greater than about 0.2 mm 2 , and wherein said plurality of apertures further define one or more aperture zones;
wherein each of said one or more aperture zones comprises four or more apertures therein; wherein each aperture within each of said aperture zones has at least three adjacent apertures.

14 . A nonwoven substrate comprising:
a) a top surface; b) a bottom surface; and c) a plurality of apertures, each of which extends from the top surface through said nonwoven substrate to the bottom surface,
wherein said plurality of apertures define a plurality of discrete non-aperture zones; wherein each of said plurality of discrete non-aperture zones has a periphery formed by a continuous line of apertures; wherein each of said plurality of discrete non-aperture zones is substantially free of apertures within the periphery; wherein the area ratio of said plurality of discrete non-aperture zones over said nonwoven substrate ranges from 60% to 90%; and wherein some of said plurality of discrete non-aperture zones have an area of 100 mm 2 or more,
wherein each of said plurality of discrete non-aperture zones has an area of more than 6 mm 2 ,
wherein each of said plurality of discrete non-aperture has a minor dimension of more than 2.5 mm, and
wherein said plurality of apertures further define one or more aperture zones; wherein each of said one or more aperture zones comprises four or more apertures therein.

15 . An absorbent article comprising a liquid pervious topsheet, a liquid impervious backsheet, an absorbent structure disposed between the topsheet and the backsheet, wherein the liquid pervious topsheet comprises the nonwoven substrate according to claim 14 .

16 . The nonwoven substrate of claim 14 , wherein the substrate has a basis weight of about 15 gsm to about 75 gsm.

17 . The nonwoven substrate of claim 14 , wherein some of said plurality of discrete non-aperture zones have a major dimension of greater than 15 mm.

18 . The nonwoven substrate of claim 14 , wherein each of said plurality of apertures has a diameter ranging from 0.5 mm to 1.5 mm.

19 . The nonwoven substrate of claim 14 , wherein a portion of said plurality of discrete non-aperture zones have an area of greater than about 150 mm 2 .

20 . An absorbent article comprising a liquid pervious topsheet, a liquid impervious backsheet, an absorbent structure disposed between the topsheet and the backsheet, wherein the liquid impervious backsheet comprises the nonwoven substrate according to claim 14 .

Assignees

• Procter & Gamble

Inventors

• Wang Sijia
• Wang Fancheng
• Wang Yuhan
• Chen Meng
• Liu Xiaoxin

Classifications

• A61F13/51401

  characterised by the material · CPC title

• A61F2013/51452

  being nonwovens · CPC title

• A61F2013/51443

  being impervious to fluids and being air permeable · CPC title

• A61F13/15707 Primary

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

• A61F2013/5127

  characterized by the dimension of apertures · CPC title