Multi-component topsheets

  • US 10,195,092 B2
  • Filed: 03/02/2015
  • Issued: 02/05/2019
  • Est. Priority Date: 03/06/2014
  • Status: Active Grant
First Claim
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1. A multi-component topsheet for an absorbent article, the topsheet comprising:

  • a) a first discrete substrate;

    b) a second discrete substrate comprising a first hydrophobic nonwoven layer and a second hydrophilic nonwoven layer; and

    c) a third discrete substrate;

    wherein the second discrete substrate is disposed at least partially intermediate the first discrete substrate and the third discrete substrate;

    wherein the second discrete substrate is joined to the first discrete substrate and the third discrete substrate;

    wherein the topsheet has a single layer of substrate in 80% or more of the total area of the topsheet and a dual layer of substrate in 20% or less of the total area of the topsheet;

    wherein a first dual layer area is formed from an overlap between the first discrete substrate and the second discrete substrate;

    wherein a second dual layer area is formed from an overlap between the second discrete substrate and the third discrete substrate;

    wherein the first and second dual layer areas together form the dual layer of substrate; and

    wherein the second discrete substrate comprises a plurality of recesses and projections, wherein the plurality of recesses and projections together form a first three-dimensional surface on a first side of the second discrete substrate and a second three-dimensional surface on a second side of the substrate, wherein the plurality of projections form enclosed dome shapes, wherein a majority of the projections are formed by the first and second nonwoven layers, wherein the majority of the projections have, according to the Projection Height Test, a z-dimensional height of between 500 μ

    m and 4000 μ

    m, and wherein a majority of the recesses define an aperture at a location most distal from a top surface of an adjacent projection, a majority of the recesses having, according to the Recess Height Test, a z-directional height of between 500 μ

    m and 2000 μ

    m.

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