THREE-DIMENSIONAL SUBSTRATES

• US 20150250662A1
• Filed: 03/02/2015
• Published: 09/10/2015
• Est. Priority Date: 03/06/2014
• Status: Active Grant

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: ISELE, Olaf Erik, ENDRES, Jrg, ROSATI, Rodrigo, WEISMAN, Paul Thomas, YOUNG, Sharon Ann, ERDEM, Gueltekin, PURDON, Mike P.
• Granted Patent: US 10,206,826 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A61F 13/51104 the top sheet having a three-dimensional cross-section, e.g. corrugations, embossments, recesses or projections
• CPC Class Codes: A61F 13/5121 characterised by the vertical shape of the apertures, e.g. three dimensional apertures, e.g. macro-apertures
• CPC Class Codes: A61F 13/5123 the apertures being formed on a multilayer top sheet
• CPC Class Codes: A61F 13/551 Packaging before or after use general packaging of absorbent pads B65D85/00
• CPC Class Codes: A61F 2013/15406 Basis weight
• CPC Class Codes: A61F 2013/51178 with the combination of nonwoven webs
• CPC Class Codes: A61F 2013/5127 characterized by the dimension of apertures
• CPC Class Codes: A61F 2013/51366 with hydrophilic lower face
• CPC Class Codes: A61F 2013/5307 characterized by the quantity or ratio of superabsorbent material
• CPC Class Codes: A61F 2013/53908 with adhesive
• CPC Class Codes: A61F 2013/8491 including test methods

Abstract

A liquid permeable substrate for an absorbent article is disclosed. The substrate comprises a first layer comprising a hydrophobic material and a second layer comprising a hydrophilic material. The first layer is joined to the second layer. The substrate comprises a plurality of recesses, a plurality of projections, and a plurality of land areas. The land areas surround at least a majority of the plurality of projections and a plurality of the recesses. The plurality of recesses, the plurality of projections, and the plurality of land areas together form a first three-dimensional surface on a first side of the substrate and a second three-dimensional surface on a second side of the substrate. The substrate has an overall z-directional height in the range of about 1000 μm to about 6000 μm according to the Overall Substrate Height Test.

Claims

1. A liquid permeable substrate for an absorbent article, the substrate comprising:

a first layer comprising a hydrophobic material; and

a second layer comprising a hydrophilic material, wherein the first layer is joined to the second layer;

wherein the substrate comprises a plurality of recesses, a plurality of projections, and a plurality of land areas, wherein the land areas surround at least a majority of the plurality of projections and a plurality of the recesses, wherein the plurality of recesses, the plurality of projections, and the plurality of land areas, together form a first three-dimensional surface on a first side of the substrate and a second three-dimensional surface on a second side of the substrate, wherein a majority of the projections have a z-directional height in the range of about 500 μ

m to about 4000 μ

m, according to the Projection Height Test, wherein a majority of the recesses define an aperture at a location most distal from a top peak of an adjacent projection, and wherein the majority of the recesses have a z-directional height in the range of about 500 μ

m to about 2000 μ

m, according to the Recess Height Test; and

wherein the substrate has an overall z-directional height in the range of about 1000 μ

m to about 6000 μ

m, according to the Overall Substrate Height Test.

2. The substrate of claim 1, wherein the first layer forms a portion of a wearer-facing surface of the absorbent article.

3. The substrate of claim 1, wherein the second layer forms a portion of a wearer-facing surface of the absorbent article.

4. The substrate of claim 1, wherein a majority of the apertures have an effective aperture area in the range of about 0.5 mm² to about 3 mm², according to the Aperture Test.

5. The substrate of claim 1, wherein the substrate has a % effective open area in the range of about 5% to about 25%, according to the Aperture Test.

6. The substrate of claim 1, wherein a portion of the projections and a portion of the recesses are formed by a portion of the first layer and a portion of the second layer.

7. The substrate of claim 1, wherein the first layer is joined to the second layer by adhesive bonding or mechanical bonding.

8. The substrate of claim 1, wherein the first layer is joined to the second layer by passing heated air through the substrate.

9. The substrate of claim 1, wherein the first layer comprises a plurality of first fibers, wherein the second layer comprises a plurality of second fibers, and wherein the first and second fibers are different.

10. The substrate of claim 1, wherein four apertures are formed around each projection.

11. The substrate of claim 1, wherein four projections are formed around each aperture.

12. The substrate of claim 1, wherein two adjacent apertures are separated by a projection and a land area along a lateral axis of the substrate, and wherein two adjacent projections are separated by an aperture and a land area along the lateral axis of the substrate.

13. The substrate of claim 1, wherein two adjacent apertures are separated by a projection and a land area along a longitudinal axis of the substrate, and wherein two adjacent projections are separated by an aperture and a land area along the longitudinal axis of the substrate.

14. The substrate of claim 1, wherein substantially all of the recesses define an aperture.

15. The substrate of claim 1, wherein substantially all of the projections comprise a hollow arched portion.

16. The substrate of claim 1, wherein the apertures comprise a first set of apertures together forming a first line in the substrate and a second set of apertures together forming a second line in the substrate, and wherein the first line is generally parallel with the second line.

17. The substrate of claim 1, wherein the apertures are formed through the first layer and the second layer.

18. The substrate of claim 1, wherein a perimeter of the majority of the apertures forms a first plane of the bottommost portion of the substrate, wherein a top peak of the majority of the projections forms a second plane of the topmost portion of the substrate, and wherein the land areas are positioned intermediate the first plane and the second plane.

19. The substrate of claim 1, wherein the first three-dimensional surface has a geometric roughness value in the range of about 3.0 to about 3.6, according to the Descriptive Analysis Roughness Test.

20. The substrate of claim 1, wherein a ratio of the z-directional height of the majority of the projections to a % effective open area of the substrate is in the range of about 95 to about 150.

21. An absorbent article comprising:

a topsheet comprising the substrate of claim 1;

a backsheet; and

an absorbent core positioned at least partially intermediate the topsheet and the backsheet, wherein the absorbent core comprises an absorbent material comprising at least 90% superabsorbent polymers by weight of the absorbent material.

22. A package comprising a plurality of the absorbent articles of claim 21, wherein the package has an in-bag stack height of less than about 80 mm, according to the In-Bag Stack Height Test.

23. The absorbent article of claim 21, wherein the absorbent article has a relative humidity of less than 70%, according to the Humidity Test, and wherein the substrate has a basis weight over 30 gsm, according to the Basis Weight Test herein.

24. The substrate of claim 1, wherein the first layer comprises fibers that are at least 0.5 denier greater than the denier of the fibers of the second layer.

25. The substrate of claim 24, wherein the first layer comprises fibers having a denier in the range of about 2 to about 4, and wherein the second layer comprises fibers having a denier in the range of about 1.5 to about 3.

26. The substrate of claim 1, wherein the first layer has a higher basis weight than the second layer.

27. The substrate of claim 1, wherein the first layer has a basis weight in the range of at least 1 to about 3 times greater than a basis weight of the second layer.

28. An absorbent article comprising an outer cover joined to a portion of a backsheet, wherein the outer cover comprises the liquid permeable substrate of claim 1.

29. The absorbent article of claim 28, comprising an outer cover that has the same or a similar appearance as the liquid permeable substrate.

31. The substrate of claim 1, wherein four apertures are formed around each projection.

32. The substrate of claim 1, wherein four projections are formed around each aperture.

30. A liquid permeable substrate for an absorbent article, the substrate comprising:

a first layer comprising a hydrophobic material; and

a second layer comprising a hydrophilic material, wherein the first layer is joined to the second layer;

wherein the substrate comprises a plurality of recesses, a plurality of projections, and a plurality of land areas, wherein the land areas surround at least a majority of the plurality of projections and a plurality of the recesses, wherein the plurality of recesses, the plurality of projections, and the plurality of land areas, together form a first three-dimensional surface on a first side of the substrate and a second three-dimensional surface on a second side of the substrate, wherein a majority of the projections have a z-directional height in the range of about 500 μ

m to about 4000 μ

m, according to the Projection Height Test, wherein a majority of the recesses define an aperture at a location most distal from a top peak of an adjacent projection, and wherein the majority of the recesses have a z-directional height in the range of about 500 μ

m to about 2000 μ

m, according to the Recess Height Test;

wherein the substrate has an overall z-directional height in the range of about 1000 μ

m to about 6000 μ

m, according to the Overall Substrate Height Test;

wherein a portion of the projections and a portion of the recesses are formed by a portion of the first layer and a portion of the second layer; and

wherein the apertures are formed through the first layer and through the second layer.

33. A liquid permeable substrate for an absorbent article, the substrate comprising:

a first layer comprising a hydrophobic material; and

a second layer comprising a hydrophilic material, wherein the first layer is joined to the second layer;

wherein the substrate comprises a plurality of recesses, a plurality of projections, and a plurality of land areas, wherein the land areas surround at least a majority of the plurality of projections and a plurality of the recesses, wherein the plurality of recesses, the plurality of projections, and the plurality of land areas, together form a first three-dimensional surface on a first side of the substrate and a second three-dimensional surface on a second side of the substrate, wherein a majority of the recesses define an aperture at a location most distal from a top peak of an adjacent projection;

wherein a portion of the projections and a portion of the recesses are formed by a portion of the first layer and a portion of the second layer; and

wherein the apertures are formed through the first layer and through the second layer;

wherein four apertures are formed around each projection; and

wherein four projections are formed around each aperture.

36. An absorbent article comprising:

a topsheet comprising the liquid permeable substrate of claim 33;

a backsheet; and

an absorbent article positioned at least partially intermediate the topsheet and the backsheet, wherein the absorbent core comprises an absorbent material comprising at least 95% superabsorbent polymers by weight of the absorbent material.

37. A package comprising a plurality of the absorbent articles of claim 36, wherein the package has an in-bag stack height of less than about 85 mm, but greater than 75 mm, according to the In-Bag Stack Height Test.

38. The absorbent article of claim 36, wherein the absorbent article has a relative humidity of less than 65%, according to the Humidity Test, and wherein the liquid permeable substrate has a basis weight of over 30 gsm, according to the Basis Weight Test.

39. The absorbent article of claim 36, wherein the absorbent article has a relative humidity of less than 70%, according to the Humidity Test, and a WVTR value of less than 6,500 g/m² day, according to Water Vapor Transmission Rate Test, and wherein the liquid permeable substrate has a basis weight of over 30 gsm, according to the Basis Weight Test.

40. The absorbent article of claim 36, wherein the absorbent article has a relative humidity of less than 60%, according to the Humidity Test, and a WVTR value of less than 14,500 g/m² day, according to the Water Vapor Transmission Rate Test, and wherein the liquid permeable substrate has a basis weight of over 30 gsm, according to the Basis Weight Test.

34. A liquid permeable substrate for an absorbent article, the substrate comprising:

a first layer comprising a hydrophobic material; and

a second layer second layer joined to the first layer and comprising a hydrophilic material;

wherein the substrate comprises a plurality of apertures, a plurality of land areas, and a plurality of projections, wherein the plurality of projections, the plurality of land areas, and the plurality of apertures together form a first three-dimensional surface on a first side of the substrate, wherein a majority of the projections have a z-directional height in the range of about 500 μ

m to about 3000 μ

m, according to the Projection Height Test, wherein a majority of the apertures are defined at a location in the substrate most distal from a top peak of an adjacent projection, and wherein the majority of the apertures have an effective aperture area in the range of about 0.5 mm² to about 4 mm², according to the Aperture Test; and

wherein the substrate has a ratio of z-directional projection height of the majority of the projections to a % effective open area of the substrate in the range of about 100 to about 145.

35. The substrate of claim 34, wherein a portion of the liquid pervious substrate is generally symmetrical about a lateral axis of the substrate and about a longitudinal axis of the substrate.