ABSORBENT ARTICLES HAVING DISCONTINUOUS BOND PATTERNS

FIELD

The present disclosure is generally directed to absorbent articles comprising discontinuous bond patterns, and, is more particularly directed to, absorbent articles comprising landing components comprising discontinuous bond patterns.

BACKGROUND

Absorbent articles may comprise diapers, pants, adult incontinence products, and sanitary napkins, for example. Absorbent articles may also comprise cleaning, dusting, mopping, and/or wiping pads or substrates, such as a Swiffer ^® pad. The absorbent articles typically comprise a liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent core positioned at least partially intermediate the topsheet and the backsheet. Various components of absorbent articles comprise nonwoven materials. Some example components are outer cover nonwoven materials, discrete, nonwoven landing zones, and non-elasticized front belts comprising one or more nonwoven materials. All of these nonwoven components may function as landing components for hooks in a taped diaper context. In a cleaning, dusting, mopping, and/or wiping pad or substrate, one or more nonwoven materials may act as a landing component for hooks on a base of a handle. To function as a landing component, these nonwoven components may need to have certain characteristics to engage hook materials of fasteners (or bases of handles) and reliably hold the hooks of the fasteners (or bases of handles). Related art landing zones relied on islands of raised material or continuous line patterns of bonds or densified areas to achieve fastening performance. These related art landing zones, however, struggled with the appearance of premium quality. However, using discontinuous line patterns of bonds on a landing zone may result in higher fuzz and undesirably fastening. As such, a balance is needed between landing component line patterns of bonds that look premium, but that have acceptable levels of fuzz and also have suitable fastening performance. As such, landing components, such as outer cover nonwoven materials, discrete, nonwoven landing zones, non-elasticized front belts comprising one or more nonwoven materials, or cleaning, dusting, mopping, and/or wiping pads or substrates comprising bond patterns, should be improved. SUMMARY

The present disclosure provides, in part, absorbent articles comprising landing components comprising one or more nonwoven materials comprising discontinuous bond patterns that have a premium look, have adequate fastening performance when receiving hooks, and that have low levels of fuzz. The landing zone components may be an outer cover nonwoven material, a discrete landing zone, a non-elasticized front belt comprising or more nonwoven materials, for example. The landing component may also comprise a cleaning, dusting, mopping, and/or wiping pad or substrate comprising one or more nonwoven materials comprising the discontinuous bond patterns.

The present disclosure provides, in part, nonwoven materials comprising discontinuous bond patterns. These nonwoven materials may be provided on any product or consumer product. The nonwoven materials, though, are especially useful as landing components, such as female components of mechanical fasteners.

The present disclosure provides, in part, absorbent articles comprising one or more nonwoven materials comprising discontinuous bond patterns. The one or more nonwoven materials may form at least a portion of a waistband, a leg cuff, a topsheet, a waist cuff, an ear, a side panel, a belt, and/or any other component or components, for example.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of the present disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following description of example forms of the disclosure taken in conjunction with the accompanying drawings, wherein:

Fig. 1 is a plan view of an example absorbent article in the form of a taped diaper, garment facing surface facing the viewer, in a flat laid-out state;

Fig. 2 is a plan view of the example absorbent article of Fig. 1 , wearer- facing surface facing the viewer, in a flat laid-out state;

Fig. 3 is a front perspective view of the absorbent article of Figs. 1 and 2 in a fastened position;

Fig. 4 is a front perspective view of an absorbent article in the form of a pant;

Fig. 5 is a rear perspective view of the absorbent article of Fig. 4;

Fig. 6 is a plan view of the absorbent article of Fig. 4, laid flat, with a garment-facing surface facing the viewer;

Fig. 7 is a cross-sectional view of the absorbent article taken about line 7— 7 of Fig. 6; Fig. 8 is a cross-sectional view of the absorbent article taken about line 8— 8 of Fig. 6;

Fig. 9 is a plan view of an example absorbent core or an absorbent article;

Fig. 10 is a cross-sectional view, taken about line 10— 10, of the absorbent core of Fig. 9;

Fig. 11 is a cross-sectional view, taken about line 11— 11, of the absorbent core of Fig. 10;

Fig. 12 is a plan view of an example absorbent article of the present disclosure that is a sanitary napkin;

Fig. 13 is a plan view of an example absorbent article in the form of a taped diaper with a discrete, non-elasticized front belt, garment- facing surface facing the viewer, in a flat laid-out state;

Fig. 14 is a plan view of the example absorbent article of Fig. 13 with a discrete, non- elasticized front belt, wearer-facing surface facing the viewer, in a flat laid-out state;

Fig. 15 is a front perspective view of the absorbent article of Figs. 13 and 14 with a discrete, non-elasticized front belt in a partially fastened position and having first and second patterns on two different components;

Fig. 16 is a front perspective view of the absorbent article of Figs. 13 and 14 with a discrete, non-elasticized front belt in a partially fastened position and having third and fourth patterns on two different components;

Fig. 17 is a plan view of a discrete, non-elasticized front belt having a first and second support members proximate to first and second ends thereof;

Fig. 18 is a cross-sectional view of the discrete, non-elasticized front belt, taken about line 18— 18 of Fig. 17;

Figs. 19 and 20 are example discontinuous bond patterns having herringbone patterns;

Figs. 21 and 22 are blown-up examples of discontinuous bond patterns having herringbone patterns;

Fig. 23 is a blown-up example of a discontinuous bond pattern having an ellipse pattern;

Fig. 24 is a blown-up example of a discontinuous bond pattern having an ellipse pattern;

Fig. 25 is a blown-up example of a discontinuous bond pattern having an ellipse pattern;

Figs. 26 and 27 are example repeat unit boundary identifications linked to the Repeat Unit/Bond Area Measurement Test herein; and

Fig. 28 is an example repeat unit boundary identification taken in a substrate comprising a repeating bond pattern linked to the Repeat Unit/Bond Area Measurement Test herein. DETAILED DESCRIPTION

Various non- limiting forms of the present disclosure will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the Absorbent Articles Having Discontinuous Bond Patterns disclosed herein. One or more examples of these non-limiting forms are illustrated in the accompanying drawings. Those of ordinary skill in the art will understand that the Absorbent Articles Having Discontinuous Bond Patterns described herein and illustrated in the accompanying drawings are non- limiting example forms and that the scope of the various non- limiting forms of the present disclosure are defined solely by the claims. The features illustrated or described in connection with one non-limiting form may be combined with the features of other non-limiting forms. Such modifications and variations are intended to be included within the scope of the present disclosure.

Prior to a detailed discussion of the absorbent articles comprising nonwoven materials comprising discontinuous bond patterns, a general discussion of absorbent articles and their various components and features will be presented as background.

General Description of an Absorbent Article

An example absorbent article 10 according to the present disclosure, shown in the form of a taped diaper, is represented in Figs. 1-3. Fig. 1 is a plan view of the example absorbent article 10, garment-facing surface 2 facing the viewer in a flat, laid-out state (i.e., no elastic contraction). Fig. 2 is a plan view of the example absorbent article 10 of Fig. 1, wearer-facing surface 4 facing the viewer in a flat, laid-out state. Fig. 3 is a front perspective view of the absorbent article 10 of Figs. 1 and 2 in a fastened configuration. The absorbent article 10 of Figs. 1-3 is shown for illustration purposes only as the present disclosure may be used for making a wide variety of diapers, including adult incontinence products, pants, or other absorbent articles, such as sanitary napkins and absorbent pads, for example.

The absorbent article 10 may comprise a front waist region 12, a crotch region 14, and a back waist region 16. The crotch region 14 may extend intermediate the front waist region 12 and the back waist region 16. The front wait region 12, the crotch region 14, and the back waist region 16 may each be 1/3 of the length of the absorbent article 10. The absorbent article 10 may comprise a front end edge 18, a back end edge 20 opposite to the front end edge 18, and longitudinally extending, transversely opposed side edges 22 and 24 defined by the chassis 52.

The absorbent article 10 may comprise a liquid permeable topsheet 26, a liquid impermeable backsheet 28, and an absorbent core 30 positioned at least partially intermediate the topsheet 26 and the backsheet 28. The absorbent article 10 may also comprise one or more pairs of barrier leg cuffs 32 with or without elastics 33, one or more pairs of leg elastics 34, one or more elastic waistbands 36, and/or one or more acquisition materials 38. The acquisition material or materials 38 may be positioned intermediate the topsheet 26 and the absorbent core 30. An outer cover nonwoven material 40 may cover a garment- facing side of the backsheet 28. The absorbent article 10 may comprise back ears 42 in the back waist region 16. The back ears 42 may comprise fasteners 46 on tapes and may extend from the back waist region 16 of the absorbent article 10 and attach (using the fasteners 46) to the landing zone area or landing zone material 44 on a garment facing portion of the front waist region 12 of the absorbent article 10. The absorbent article 10 may also have front ears 47 in the front waist region 12. The absorbent article 10 may have a central lateral (or transverse) axis 48 and a central longitudinal axis 50. The central lateral axis 48 extends perpendicular to the central longitudinal axis 50.

In other instances, the absorbent article may be in the form of a pant having permanent or refastenable side seams. Suitable refastenable seams are disclosed in U.S. Pat. Appl. Pub. No. 2014/0005020 and U.S. Pat. No. 9,421,137. Referring to Figs. 4-8, an example absorbent article 10 in the form of a pant is illustrated. Fig. 4 is a front perspective view of the absorbent article 10. Fig. 5 is a rear perspective view of the absorbent article 10. Fig. 6 is a plan view of the absorbent article 10, laid flat, with the garment-facing surface facing the viewer. Elements of Fig. 4-8 having the same reference number as described above with respect to Figs. 1-3 may be the same element (e.g., absorbent core 30). Fig. 7 is an example cross-sectional view of the absorbent article taken about line 7— 7 of Fig. 6. Fig. 8 is an example cross-sectional view of the absorbent article taken about line 8— 8 of Fig. 6. Figs. 7 and 8 illustrate example forms of front and back belts 54, 56. The absorbent article 10 may have a front waist region 12, a crotch region 14, and a back waist region 16. Each of the regions 12, 14, and 16 may be 1/3 of the length of the absorbent article 10. The absorbent article 10 may have a chassis 52 (sometimes referred to as a central chassis or central panel) comprising a topsheet 26, a backsheet 28, and an absorbent core 30 disposed at least partially intermediate the topsheet 26 and the backsheet 28, and an optional acquisition material 38, similar to that as described above with respect to Figs. 1-3. The absorbent article 10 may comprise a front belt 54 in the front waist region 12 and a back belt 56 in the back waist region 16. The chassis 52 may be joined to a wearer- facing surface 4 of the front and back belts 54, 56 or to a garment- facing surface 2 of the belts 54, 56. Side edges 23 and 25 of the front belt 54 may be joined to side edges 27 and 29, respectively, of the back belt 56 to form two side seams 58. The side seams 58 may be any suitable seams known to those of skill in the art, such as butt seams or overlap seams, for example. When the side seams 58 are permanently formed or refastenably closed, the absorbent article 10 in the form of a pant has two leg openings 60 and a waist opening circumference 62. The side seams 58 may be permanently joined using adhesives or bonds, for example, or may be refastenably closed using hook and loop fasteners, for example.

Belts

Referring to Figs. 7 and 8, the front and back belts 54 and 56 may comprise front and back inner belt layers 66 and 67 and front and back outer belt layers 64 and 65 having an elastomeric material (e.g., strands 68 or a film (which may be apertured)) disposed at least partially therebetween. The elastic elements 68 or the film may be relaxed (including being cut) to reduce elastic strain over the absorbent core 30 or, may alternatively, run continuously across the absorbent core 30. The elastics elements 68 may have uniform or variable spacing therebetween in any portion of the belts. The elastic elements 68 may also be pre-strained the same amount or different amounts. The front and/or back belts 54 and 56 may have one or more elastic element free zones 70 where the chassis 52 overlaps the belts 54, 56. In other instances, at least some of the elastic elements 68 may extend continuously across the chassis 52.

The front and back inner belt layers 66, 67 and the front and back outer belt layers 64, 65 may be joined using adhesives, heat bonds, pressure bonds or thermoplastic bonds. Various suitable belt layer configurations can be found in U.S. Pat. Appl. Pub. No. 2013/0211363.

Front and back belt end edges 55 and 57 may extend longitudinally beyond the front and back chassis end edges 19 and 21 (as shown in Fig. 6) or they may be co-terminus. The front and back belt side edges 23, 25, 27, and 29 may extend laterally beyond the chassis side edges 22 and 24. The front and back belts 54 and 56 may be continuous (i.e., having at least one layer that is continuous) from belt side edge to belt side edge (e.g., the transverse distances from 23 to 25 and from 27 to 29). Alternatively, the front and back belts 54 and 56 may be discontinuous from belt side edge to belt side edge (e.g., the transverse distances from 23 to 25 and 27 to 29), such that they are discrete.

As disclosed in U.S. Pat. No. 7,901,393, the longitudinal length (along the central longitudinal axis 50) of the back belt 56 may be greater than the longitudinal length of the front belt 54, and this may be particularly useful for increased buttocks coverage when the back belt 56 has a greater longitudinal length versus the front belt 54 adjacent to or immediately adjacent to the side seams 58. The front outer belt layer 64 and the back outer belt layer 65 may be separated from each other, such that the layers are discrete or, alternatively, these layers may be continuous, such that a layer runs continuously from the front belt end edge 55 to the back belt end edge 57. This may also be true for the front and back inner belt layers 66 and 67 - that is, they may also be longitudinally discrete or continuous. Further, the front and back outer belt layers 64 and 65 may be longitudinally continuous while the front and back inner belt layers 66 and 67 are longitudinally discrete, such that a gap is formed between them - a gap between the front and back inner and outer belt layers 64, 65, 66, and 67 is shown in Fig. 7 and a gap between the front and back inner belt layers 66 and 67 is shown in Fig. 8.

The front and back belts 54 and 56 may include slits, holes, and/or perforations providing increased breathability, softness, and a garment-like texture. Underwear- like appearance can be enhanced by substantially aligning the waist and leg edges at the side seams 58 (see Figs. 4 and 5).

The front and back belts 54 and 56 may comprise graphics (see e.g., 78 of Fig. 1). The graphics may extend substantially around the entire circumference of the absorbent article 10 and may be disposed across side seams 58 and/or across proximal front and back belt seams 15 and 17; or, alternatively, adjacent to the seams 58, 15, and 17 in the manner described in U.S. Pat. No. 9,498, 389 to create a more underwear-like article. The graphics may also be discontinuous. The front and/or back belts may comprise the nonwoven materials comprising the discontinuous bond patterns described herein.

Alternatively, instead of attaching belts 54 and 56 to the chassis 52 to form a pant, discrete side panels may be attached to side edges of the chassis 22 and 24.

Topsheet

The topsheet 26 is the part of the absorbent article 10 that is in contact with the wearer’s skin. The topsheet 26 may be joined to portions of the backsheet 28, the absorbent core 30, the barrier leg cuffs 32, and/or any other layers as is known to those of ordinary skill in the art. The topsheet 26 may be compliant, soft-feeling, and non-irritating to the wearer's skin. Further, at least a portion of, or all of, the topsheet may be liquid permeable, permitting liquid bodily exudates to readily penetrate through its thickness. A suitable topsheet may be manufactured from a wide range of materials, such as porous foams, reticulated foams, apertured plastic films, woven materials, nonwoven materials, woven or nonwoven materials of natural fibers (e.g., wood or cotton fibers), synthetic fibers or filaments (e.g., polyester or polypropylene or bicomponent PE/PP fibers or mixtures thereof), or a combination of natural and synthetic fibers. The topsheet may have one or more layers. The topsheet may be apertured (Fig. 2, element 31), may have any suitable three-dimensional features, and/or may have a plurality of embossments (e.g., a bond pattern). The topsheet may be apertured by overbonding a material and then rupturing the overbonds through ring rolling, such as disclosed in U.S. Patent No. 5,628,097, to Benson et al., issued on May 13, 1997 and disclosed in U.S. Pat. Appl. Publication No. US 2016/0136014 to Arora et al. Any portion of the topsheet may be coated with a skin care composition, an antibacterial agent, a surfactant, and/or other beneficial agents. The topsheet may be hydrophilic or hydrophobic or may have hydrophilic and/or hydrophobic portions or layers. If the topsheet is hydrophobic, typically apertures will be present so that bodily exudates may pass through the topsheet. The topsheet may comprise one or more nonwoven materials comprising the discontinuous bond patterns discussed herein. The topsheet may also comprise apertures and/or three-dimensional features.

Backsheet

The backsheet 28 is generally that portion of the absorbent article 10 positioned proximate to the garment-facing surface of the absorbent core 30. The backsheet 28 may be joined to portions of the topsheet 26, the outer cover nonwoven material 40, the absorbent core 30, and/or any other layers of the absorbent article by any attachment methods known to those of skill in the art. The backsheet 28 prevents, or at least inhibits, the bodily exudates absorbed and contained in the absorbent core 10 from soiling articles such as bedsheets, undergarments, and/or clothing. The backsheet is typically liquid impermeable, or at least substantially liquid impermeable. The backsheet may, for example, be or comprise a thin plastic film, such as a thermoplastic film having a thickness of about 0.012 mm to about 0.051 mm. Other suitable backsheet materials may include breathable materials which permit vapors to escape from the absorbent article, while still preventing, or at least inhibiting, bodily exudates from passing through the backsheet.

Outer Cover Nonwoven Material

The outer cover nonwoven material (sometimes referred to as a backsheet nonwoven) 40 may comprise one or more nonwoven materials joined to the backsheet 28 and that covers the backsheet 28. The outer cover nonwoven material 40 forms at least a portion of the garment-facing surface 2 of the absorbent article 10 and effectively“covers” the backsheet 28 so that film is not present on the garment-facing surface 2. The outer cover nonwoven material 40 may comprise one or more nonwoven materials comprising the discontinuous bond patterns discussed herein. Absorbent Core

As used herein, the term“absorbent core” 30 refers to the component of the absorbent article 10 having the most absorbent capacity and that comprises an absorbent material. Referring to Figs. 9-11, in some instances, absorbent material 72 may be positioned within a core bag or a core wrap 74. The absorbent material may be profiled or not profiled, depending on the specific absorbent article. The absorbent core 30 may comprise, consist essentially of, or consist of, a core wrap, absorbent material 72, and glue enclosed within the core wrap. The absorbent material may comprise superabsorbent polymers, a mixture of superabsorbent polymers and air felt, only air felt, and/or a high internal phase emulsion foam. In some instances, the absorbent material may comprise at least 80%, at least 85%, at least 90%, at least 95%, at least 99%, or up to 100% superabsorbent polymers, by weight of the absorbent material. In such instances, the absorbent material may be free of air felt, or at least mostly free of air felt. The absorbent core periphery, which may be the periphery of the core wrap, may define any suitable shape, such as rectangular “T,”“Y,”“hour-glass,” or“dog-bone” shaped, for example. An absorbent core periphery having a generally“dog bone” or“hour-glass” shape may taper along its width towards the crotch region 14 of the absorbent article 10.

Referring to Figs. 9-11, the absorbent core 30 may have areas having little or no absorbent material 72, where a wearer-facing surface of the core bag 74 may be joined to a garment-facing surface of the core bag 74. These areas having little or no absorbent material and may be referred to as“channels” 76. These channels can embody any suitable shapes and any suitable number of channels may be provided. In other instances, the absorbent core may be embossed to create the impression of channels. The absorbent core in Figs. 9-11 is merely an example absorbent core. Many other absorbent cores with or without channels are also within the scope of the present disclosure.

Barrier Leg Cuffs/Leg Elastics

Referring to Figs. 1 and 2, for example, the absorbent article 10 may comprise one or more pairs of barrier leg cuffs 32 and one or more pairs of leg elastics 34. The barrier leg cuffs 32 may be positioned laterally inboard of leg elastics 34. Each barrier leg cuff 32 may be formed by a piece of material which is bonded to the absorbent article 10 so it can extend upwards from a wearer-facing surface 4 of the absorbent article 10 and provide improved containment of body exudates approximately at the junction of the torso and legs of the wearer. The barrier leg cuffs 32 are delimited by a proximal edge joined directly or indirectly to the topsheet and/or the backsheet and a free terminal edge, which is intended to contact and form a seal with the wearer’ s skin. The barrier leg cuffs 32 may extend at least partially between the front end edge 18 and the back end edge 20 of the absorbent article 10 on opposite sides of the central longitudinal axis 50 and may be at least present in the crotch region 14. The barrier leg cuffs 32 may each comprise one or more elastics 33 (e.g., elastic strands or strips) near or at the free terminal edge. These elastics 33 cause the barrier leg cuffs 32 to help form a seal around the legs and torso of a wearer. The leg elastics 34 extend at least partially between the front end edge 18 and the back end edge 20. The leg elastics 34 essentially cause portions of the absorbent article 10 proximate to the chassis side edges 22, 24 to help form a seal around the legs of the wearer. The leg elastics 34 may extend at least within the crotch region 14. The barrier leg cuffs may comprise one or more nonwoven materials comprising the discontinuous bond patterns discussed herein.

Elastic Waistband

Referring to Figs. 1 and 2, the absorbent article 10 may comprise one or more elastic waistbands 36. The elastic waistbands 36 may be positioned on the garment-facing surface 2 or the wearer-facing surface 4. As an example, a first elastic waistband 36 may be present in the front waist region 12 near the front belt end edge 18 and a second elastic waistband 36 may be present in the back waist region 16 near the back end edge 20. The elastic waistbands 36 may aid in sealing the absorbent article 10 around a waist of a wearer and at least inhibiting bodily exudates from escaping the absorbent article 10 through the waist opening circumference. In some instances, an elastic waistband may fully surround the waist opening circumference of an absorbent article. The elastic waistband may comprise one or more nonwoven materials comprising the discontinuous bond patterns discussed herein.

Acquisition Materials

Referring to Figs. 1, 2, 7, and 8, one or more acquisition materials 38 may be present at least partially intermediate the topsheet 26 and the absorbent core 30. The acquisition materials 38 are typically hydrophilic materials that provide significant wicking of bodily exudates. These materials may dewater the topsheet 26 and quickly move bodily exudates into the absorbent core 30. The acquisition materials 38 may comprise one or more nonwoven materials, foams, cellulosic materials, cross-linked cellulosic materials, air laid cellulosic nonwoven materials, spunlace materials, or combinations thereof, for example. In some instances, portions of the acquisition materials 38 may extend through portions of the topsheet 26, portions of the topsheet 26 may extend through portions of the acquisition materials 38, and/or the topsheet 26 may be nested with the acquisition materials 38. Typically, an acquisition material 38 may have a width and length that are smaller than the width and length of the topsheet 26. The acquisition material may be a secondary topsheet in the feminine pad context. The acquisition material may have one or more channels as described above with reference to the absorbent core 30 (including the embossed version). The channels in the acquisition material may align or not align with channels in the absorbent core 30. In an example, a first acquisition material may comprise a nonwoven material and as second acquisition material may comprise a cross-linked cellulosic material.

Landing Zone

Referring to Figs. 1 and 2, the absorbent article 10 may have a discrete landing zone area 44 that is formed on a portion of the garment-facing surface 2 of the outer cover nonwoven material 40. The landing zone area 44 may be in the back waist region 16 if the absorbent article 10 fastens from front to back or may be in the front waist region 12 if the absorbent article 10 fastens back to front. The landing zone 44 may be or may comprise one or more discrete nonwoven materials that are attached to a portion of the outer cover nonwoven material 40 in the front waist region 12 or the back waist region 16 depending upon whether the absorbent article fastens in the front or the back. In essence, the landing zone 44 is configured to receive the fasteners 46 and may comprise, for example, a plurality of loops configured to be engaged with, a plurality of hooks on the fasteners 46, or vice versa. The landing zone 44 may comprise one or more nonwoven materials comprising the discontinuous bond patterns discussed herein.

Wetness Indicator/Graphics

Referring to Fig. 1, the absorbent articles 10 of the present disclosure may comprise graphics 78 and/or wetness indicators 80 that are visible from the garment-facing surface 2. The graphics 78 may be printed on the landing zone 44, the backsheet 28, and/or at other locations. The wetness indicators 80 are typically applied to the absorbent core facing side of the backsheet 28, so that they can be contacted by bodily exudates within the absorbent core 30. In some instances, the wetness indicators 80 may form portions of the graphics 78. For example, a wetness indicator may appear or disappear and create/remove a character within some graphics. In other instances, the wetness indicators 80 may coordinate (e.g., same design, same pattern, same color) or not coordinate with the graphics 78. Front and Back Ears

Referring to Figs. 1 and 2, as referenced above, the absorbent article 10 may have front and/or back ears 47, 42 in a taped diaper context. Only one set of ears may be required in most taped diapers. The single set of ears may comprise fasteners 46 comprising hooks configured to engage the landing zone or landing zone area 44. If two sets of ears are provided, in most instances, only one set of the ears may have fasteners 46 comprising the hooks, with the other set being free of fasteners comprising hooks. The ears, or portions thereof, may be elastic or may have elastic panels. In an example, an elastic film or elastic strands may be positioned intermediate a first nonwoven material and a second nonwoven material. The elastic film may or may not be apertured. The ears may be shaped. The ears may be integral (e.g., extension of the outer cover nonwoven material 40, the backsheet 28, and/or the topsheet 26) or may be discrete components attached to a chassis 52 of the absorbent article on a wearer-facing surface 4, on the garment-facing surface 2, or intermediate the two surfaces 4, 2. The ears may comprise one or more nonwoven materials comprising bond patterns, apertures, and/or three-dimensional features. The back and/or front ears may each comprise tapes comprising fasteners 46. The front and/or back ears may comprise one or more nonwoven materials comprising the discontinuous bond patterns discussed herein. If the discontinuous bond patterns are provided on nonwoven materials of garment-facing surfaces of the fasteners 46, hooks of one fastener may be able to fasten to the nonwoven material on the garment facing side of another faster (i.e., overlapping fasteners).

Sensors

Referring again to Fig. 1, the absorbent articles of the present disclosure may comprise a sensor system 82 for monitoring changes within the absorbent article 10. The sensor system 82 may be discrete from or integral with the absorbent article 10. The absorbent article 10 may comprise sensors that can sense various aspects of the absorbent article 10 associated with insults of bodily exudates such as urine and/or BM (e.g., the sensor system 82 may sense variations in temperature, humidity, presence of ammonia or urea, various vapor components of the exudates (urine and feces), changes in moisture vapor transmission through the absorbent articles garment facing layer, changes in translucence of the garment- facing layer, and/or color changes through the garment-facing layer). Additionally, the sensor system 82 may sense components of urine, such as ammonia or urea and/or byproducts resulting from reactions of these components with the absorbent article 10. The sensor system 82 may sense byproducts that are produced when urine mixes with other components of the absorbent article 10 (e.g., adhesives, agm). The components or byproducts being sensed may be present as vapors that may pass through the garment-facing layer. It may also be desirable to place reactants in the absorbent article that change state (e.g. color, temperature) or create a measurable byproduct when mixed with urine or BM. The sensor system 82 may also sense changes in pH, pressure, odor, the presence of gas, blood, a chemical marker or a biological marker or combinations thereof. The sensor system 82 may have a component on or proximate to the absorbent article that transmits a signal to a receiver more distal from the absorbent article, such as an iPhone, for example. The receiver may output a result to communicate to the caregiver a condition of the absorbent article 10. In other instances, a receiver may not be provided, but instead the condition of the absorbent article 10 may be visually or audibly apparent from the sensor on the absorbent article.

Packages

The absorbent articles of the present disclosure may be placed into packages. The packages may comprise polymeric films and/or other materials. Graphics and/or indicia relating to properties of the absorbent articles may be formed on, printed on, positioned on, and/or placed on outer portions of the packages. Each package may comprise a plurality of absorbent articles. The absorbent articles may be packed under compression so as to reduce the size of the packages, while still providing an adequate number of absorbent articles per package. By packaging the absorbent articles under compression, caregivers can easily handle and store the packages, while also providing distribution savings to manufacturers owing to the size of the packages. The packages may have discontinuous bond patterns and/or three-dimensional features that match or are similar to discontinuous bond patterns, apertures, and/or three-dimensional features on nonwoven materials of the absorbent articles within the packages.

Sanitary Nankin

Referring to Fig. 12, an absorbent article of the present disclosure may be a sanitary napkin 110. The sanitary napkin 110 may comprise a liquid permeable topsheet 114, a liquid impermeable, or substantially liquid impermeable, backsheet 116, and an absorbent core 118. The liquid impermeable backsheet 116 may or may not be vapor permeable. The absorbent core 118 may have any or all of the features described herein with respect to the absorbent core 30 and, in some forms, may have a secondary topsheet 119 (STS) instead of the acquisition materials disclosed above. The STS 119 may comprise one or more channels, as described above (including the embossed version). In some forms, channels in the STS 119 may be aligned with channels in the absorbent core 118. The sanitary napkin 110 may also comprise wings 120 extending outwardly with respect to a longitudinal axis 180 of the sanitary napkin 110. The sanitary napkin 110 may also comprise a lateral axis 190. The wings 120 may be joined to the topsheet 114, the backsheet 116, and/or the absorbent core 118. The sanitary napkin 110 may also comprise a front edge 122, a back edge 124 longitudinally opposing the front edge 122, a first side edge 126, and a second side edge 128 longitudinally opposing the first side edge 126. The longitudinal axis 180 may extend from a midpoint of the front edge 122 to a midpoint of the back edge 124. The lateral axis 190 may extend from a midpoint of the first side edge 128 to a midpoint of the second side edge 128. The sanitary napkin 110 may also be provided with additional features commonly found in sanitary napkins as is known in the art. The sanitary napkin 110 may comprise one or more nonwoven materials comprising the discontinuous bond patterns discussed herein.

Pads or Substrates

The absorbent articles discussed herein may comprise cleaning, wiping, dusting, and/or mopping pads or substrates (e.g., wipes). These products may comprise one or more nonwoven materials comprising the discontinuous bond patterns discussed herein. The pads may comprise a topsheet, a backsheet, and an absorbent core positioned at least partially therebetween. The one or more nonwoven materials may be in a facing relationship with the backsheet. The one or more nonwoven materials may function as a female component of a mechanical fastener that is configured to engage hooks on a base of a handle or implement. The discontinuous bond pattern may extend over a portion of, or all of, a surface of the one or more nonwoven materials which are configured to face hooks on the base of the handle or implement. One example product is a Swiffer ^® Wet Jet pad manufactured by the Procter & Gamble Company of Cincinnati, Ohio. An example of such a pad is disclosed in U.S. Patent No. 10,065,534 to Hoying et al.

Garment-Like Absorbent Articles

Some garment-like absorbent articles of the present disclosure may have at least two different nonwoven absorbent article components that have discontinuous bond patterns thereon. In some instances, one bond pattern may be on the garment- facing surface 2 and the other bond pattern may be on the wearer-facing surface 4, for example. On some non-landing zone components, the patterns may be formed by apertures, bonds, printing, and/or graphics. If functioning as a landing component, the patterns may be discontinuous bond patterns. Bonds, including discontinuous bonds, as used herein, may comprise thermal bonds, ultrasonic bonds, pressure bonds, heat and pressure bonds, embossments, embossments that form three-dimensional features, and/or mechanical deformations that produce three-dimensional features, for example. The various nonwoven absorbent article components may be or may comprise at least a portion of a topsheet, an ear, a leg cuff, an outer cover nonwoven material, a discrete landing zone, a discrete, non-elasticized front belt, an ear, a wing of a sanitary napkin, a belt of a pant, a waistband, or various other absorbent article components, for example.

An example discrete landing zone 44 is illustrated in Fig. 1. By discrete landing zone, it is meant that the landing zone is a separate component from the outer cover nonwoven material 40 and not just a portion of the outer cover nonwoven material 40. The discrete landing zone may be one piece or may be multiple pieces, as illustrated in Fig. 1 with dashed lines. If two pieces are desired, a first piece 44’ may be spaced a distance from a second piece 44’’ such that the first piece 44’ does not overlap or contact the second piece 44”. The discrete landing zone, whether one or two pieces, may be attached to a garment-facing surface 2 of the absorbent article. The discrete landing zone 44 may comprise the discontinuous bond patterns discussed herein.

An example of a discrete, non-elasticized front belt 200 is illustrated in Figs. 13-16. In some instances, the front belt 200 may be elasticized or partially elasticized. The discrete, non- elasticized front belt 200 may be a separate material attached to the garment-facing surface 2 and/or the wearer-facing surface 4 of the absorbent article 10. The front belt 200 may form front ear portions on either side of the chassis 52.

In an instance, a first portion of the outer cover nonwoven material may have the first pattern and a second portion of the outer cover nonwoven material may have the second pattern. In such an instance, the second portion may act as a landing zone and may comprise the discontinuous bond patterns discussed herein.

Referring to Fig. 15, the outer cover nonwoven material 40 may have a first repeating pattern 204 of discontinuous bonds 212. The first repeating pattern 204 may have a plurality of first repeat units 214. A portion of the first repeating pattern 204 within at least a majority of the first repeat units 214 may be the same or substantially the same (e.g., process tolerances).

The discrete, non-elasticized front belt 200, or discrete landing zone, (e.g., second component) may have a second repeating pattern 202 of discontinuous bonds 216. The second repeating pattern 202 may have a plurality of second repeat units 218. A portion of the second repeating pattern 202 within at least a majority of the second repeat units 218 may be the same or substantially the same (e.g., process tolerances). The first texture of the first pattern 204 and the second texture of the second pattern 202 may be the same (accounting for process tolerances) or different. At least some of, or all of, the first repeat units 214 comprising the portion of the first pattern 204 may comprise a first shape. At least some of, or all of, the second repeat units 218 comprising the portion of the second pattern 202 may comprise a second shape. The first shape may be the same as or substantially similar to the second shape. For example, the first repeat units 214 may comprise ellipses and the second repeat units 218 may comprise ellipses, as illustrated in Fig. 15. As another example, the first repeat units 214 may comprise triangles, wavy lines, squares, ovals, clouds, hearts, and/or other shapes or patterns and the second repeat units may also comprise triangles, wavy lines, squares, ovals, clouds, hearts, and/or other shapes or patterns. Even though the first and second repeat units may comprise similar shapes or patterns, the size of the shapes or patterns may vary between the first and second repeat units. Also, the density and/or size of the apertures and/or bonds in the various repeat units may differ. Likewise, in some instances, the first pattern 204 may be different than the second pattern 202, although such patterns may correspond or be substantially similar to create a garment-like impression in the absorbent article.

Even though the at least two nonwoven components of an absorbent article are described herein as being complimentary to each other, they may also be used separate from one another or may be the same (including process tolerances). For example, an outer cover nonwoven material having the discontinuous bond patterns discussed herein may be used in an absorbent article separate from the discrete landing zone or discrete, non-elasticized front belt having the discontinuous bond patterns discussed herein. The same applies to the discrete landing zone or discrete, non-elasticized front belt without the outer cover nonwoven material.

Referring to Fig. 16, the outer cover nonwoven material 40 (e.g., first component) may comprise a first repeating pattern 208 of discontinuous bonds 220. The first repeating pattern 208 may have a plurality of first repeat units 222. A portion of the first repeating pattern 208 within at least a majority of the first repeat units 222 may be the same or substantially the same (process tolerances). The first repeating pattern 208 may form a herringbone pattern.

The discrete, non-elasticized front belt 200, or discrete landing zone, (e.g., second component) may have a second repeating pattern 206 of discontinuous bonds 224. The second repeating pattern 206 may have a plurality of second repeat units 226. A portion of the second repeating pattern 206 within at least a majority of the second repeat units 226 may be the same or substantially the same (e.g., process tolerances). The second repeating pattern 206 may form a herringbone pattern. Referring to Figs. 16-18, the discrete, non-elasticized front belt 200 may have a middle portion 228 that overlaps the outer cover nonwoven material. The front belt 200 may comprise a first lateral end 230 and a second, opposing lateral end 232. A first portion 234 of the front belt 200 may be positioned intermediate the first lateral end 230 and a first lateral edge of the outer cover nonwoven material. A second portion 236 of the front belt 200 may be positioned intermediate the second lateral end 232 and a second, opposing lateral edge of the outer cover nonwoven material. These first and second portions 234, 236 are free of overlap with the outer cover nonwoven material and, therefore, may be flimsy and not appear of high quality. To solve this issue, a support member 210 may overlap and be joined to the first and second portions 234, 236 to provide structural support to the first and second portions 234, 236. The support members may be a nonwoven material, a foam, a felt, a film, a cellulosic material or other suitable material that for providing support to the first and second portions 234, 236 of the front belt 200 that are free of overlap with the outer cover nonwoven material. A support member may also be the full dimensions, or less than the full dimensions, of the discrete, non-elasticized front belt. In other instances, no support member(s) may be provided on a front belt.

Absorbent Articles with Discontinuous Bond Patterns

Herringbone Discontinuous Bond Pattern

Figs. 19 and 20 are example discontinuous bond patterns 300 for landing components of absorbent articles, such as outer cover nonwoven materials, discrete landing zones, discrete, non- elasticized front belts, and/or nonwoven materials or other components. These discontinuous bond patterns for landing components are optimized for reliable fastening and are configured to receive hooks of a fastener 46. The discontinuous bond patterns may also be used for non-landing zone components, such as topsheets, secondary topsheets, portions of an outer cover nonwoven material not configured to receive hooks, ears, side panels, leg cuffs, and/or waistbands, for example. The discontinuous bond patterns may have a bond area in the range of about 8% to about 30%, about 10% to about 25%, about 12% to about 23%, about 14% to about 20%, for example. Bond areas are measured according to the Repeat Unit/Bond Areas Measurement Test herein. Axis 301 may or may not be generally parallel to the central longitudinal axis 50 (see Fig. 1) and axis 303 may or may not be generally parallel to the central lateral axis 48 (see Fig. 1). In some instances, axis 301 may be angled with respect to the central longitudinal axis 50, such as angled in the range of about 0.5 degrees to about 20 degrees, or about 1 degree to about 15 degrees, for example. This angling may reduce wear on bonding rolls comprising the discontinuous bond pattern. Axis 301 and 303 may be the same as described here in Figs. 21 and 22.

Fig. 21 is an example of a blown-up portion of a discontinuous bond pattern 300 for landing components of absorbent articles, nonwoven materials, or other components. Fig. 22 is an example of a blown-up portion of a discontinuous bond pattern 300 for landing components of absorbent articles, nonwoven materials, or other components. Referring to Fig. 21, the discontinuous bond pattern 300 may comprise a first plurality of first discontinuous elements 302 forming a first discontinuous line 304. The discontinuous bond pattern 300 may comprise a second plurality of second discontinuous elements 306 forming a second discontinuous line 308. The discontinuous bond pattern 300 may comprise a third plurality of third discontinuous elements 310 positioned intermediate the first discontinuous line 304 and the second discontinuous line 308, wherein the plurality of third discontinuous elements 310 form a third discontinuous line 312 that extends in a direction transverse to a direction of extension of the first and second discontinuous lines 304, 308. The third discontinuous line 312 may extend in a direction in the range of about 15 degrees to about 75 degrees, or about 30 degrees to about 60 degrees, relative to the direction of extension of the first and second discontinuous lines 304, 308, specifically reciting all 0.1 degree increments within the specified ranges and all ranges formed therein or thereby. The first discontinuous line 304, the second discontinuous line 308, and the third discontinuous line 312 may all be free of overlap with any portion of each other. In other instances, some portions of the first discontinuous line 304, the second discontinuous line 308, and the third discontinuous line 312 may at least partially overlap. A distance, D, in a direction perpendicular to the first discontinuous line 304, between the first discontinuous line 304 and the second discontinuous line 308 may be in the range of about 3mm to about 15mm, about 2mm to about 12mm, about 3mm to about 10mm, about 4mm to about 8mm, about 5mm to about 7mm, about 6mm to about 7mm, or about 6.5mm, specifically reciting all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby. The first discontinuous line 304 may extend in a direction parallel (accounting for process tolerances), or substantially parallel (e.g., +/- 3 degrees) to the second discontinuous line 308.

The first discontinuous elements 302 (any of the first discontinuous elements 302 in the first discontinuous line 304) may comprise a first element 302a and second element 302b that are different in size and/or shape and may comprise a third element 302c and a fourth element 302d that are the same in size and/or shape or substantially the same in size and/or shape (process tolerances). The first discontinuous elements 302 in the first line 304 may also be all the same size and shape, may comprise two or more different sizes and/or shapes, may comprise three and/or more different shapes (see pattern in Fig. 22), may comprise four or more different sizes and/or shapes, or may comprise five or more different sizes and/or shapes, up to 10 different sizes and/or shapes, for example. The second discontinuous elements 306 (any of the second discontinuous elements 306 in the second discontinuous line 308) may comprise a first element 306a and second element 306b that are different in size and/or shape and may comprise a third element 306c and a fourth element 306d that are the same in size and/or shape, or substantially the same in size and/or shape (process tolerances). The second discontinuous elements 306 in the second line 308 may also be all the same size and shape, may comprise two or more different sizes and/or shapes, may comprise three and/or more different shapes (see pattern in Fig. 22), may comprise four or more different sizes and/or shapes, or may comprise five or more different sizes and/or shapes, up to 10 different sizes and/or shapes.

The third discontinuous line 312 may comprise a first element 310a and a second element 310b. The first element 310a and the second element 310b may be the same in size and/or shape, substantially the same in size and/or shape (process tolerances) or may be different in size and/or shape. Although only two third discontinuous elements 310 are illustrated in the discontinuous bond patterns Figs. 21 and 22, more than two third discontinuous elements 310 may be used. The first element 310a may have a positive or a negative slope relative to the central lateral axis 48 of the absorbent article 10 when on the landing component. The second element 310b may have the same positive or negative slope relative to the central lateral axis 48 of the absorbent article 10. In some instances, the first and second elements 310a and 310b may have a slight different slope (e.g., +/- 3 degrees), or a different slope (e.g., +/-10 degrees) relative to the central lateral axis 48. As can be seen in Figs. 21 and 22, the first and second discontinuous lines 304 and 308 may be longer than the third discontinuous line 312. The first and second discontinuous lines 304 and 308 may both have the same length, or substantially the same length (process tolerances).

Referring to Fig. 22, the discontinuous bond pattern 300 may comprise a fourth plurality of fourth discontinuous elements 314 forming a fourth discontinuous line 316, wherein the fourth discontinuous line 316 is positioned intermediate the first discontinuous line 304 and the second discontinuous line 312. A distance, Dl, between the third discontinuous line 312 and the fourth discontinuous line 316, in a direction parallel to the first and/or second discontinuous lines 304 and 308, may be in the range of about 1 mm to about 8mm, about 1 mm to about 6mm, about 1.5mm to about 5mm, about 2mm to about 4mm, or about 3mm, specifically reciting all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby. The third discontinuous line 312 may or may not extend in a direction parallel to, or substantially parallel to (e.g., +/- 1-3 degrees), the fourth discontinuous line 316. The fourth continuous line 316 may have the same features as discussed above with respect to the third discontinuous line 312.

Referring again to Fig. 22, the discontinuous bond pattern 300 may comprise a fifth plurality of fifth discontinuous elements 318 forming a fifth discontinuous line 320. In the claims, the“fifth” may be referred to as the“fourth” or some other number depending on what order the discontinuous lines or discontinuous elements are being discussed. This may be true for many of the discontinuous elements and the discontinuous lines. The fifth discontinuous line 320 may be the same as the first and second discontinuous lines 304, 308 and may have the same features as discussed above. The discontinuous bond pattern 300 may comprise a sixth plurality of sixth discontinuous elements 322 forming a sixth discontinuous line 324. The sixth discontinuous line 324 may have the same features as discussed above with respect to the third and fourth discontinuous lines 312 and 316. The sixth discontinuous line 324 may be positioned intermediate the second discontinuous line 308 and the fourth discontinuous line 320 and may extend in a direction transverse to the second and fourth discontinuous lines 308 and 316. The sixth discontinuous line 324 may have the same spacing and angles as discussed above with respect to the third and fourth discontinuous lines 312 and 316.

The discontinuous bond pattern 300 may comprise a seventh plurality of seventh discontinuous elements 326 forming a seventh discontinuous line 328. The seventh discontinuous line 328 may have the same features as discussed above with respect to the third and fourth discontinuous lines 312 and 316. The seventh discontinuous line 328 may be positioned intermediate the second discontinuous line 308 and the fourth discontinuous line 320 and may extend in a direction transverse to the second and fourth discontinuous lines 308 and 316. The seventh discontinuous line 328 may have the same spacing and angles as discussed above with respect to the third and fourth discontinuous lines 312 and 316.

The sixth and seventh discontinuous lines 324 and 328 may be symmetrical, or substantially symmetrical (process tolerances), to the third and fourth discontinuous lines 312 and 316 about the second discontinuous line 308. Stated another way, the sixth and seventh discontinuous lines 324 and 328 may be a mirror image, or a substantially mirror image (process tolerances) of the third and fourth discontinuous lines 312 and 316 about the second discontinuous line 308.

A number of other lines other than the first, second, third, fourth, fifth, sixth, and seventh discontinuous lines are part of the discontinuous bond pattern. For brevity, each additional line will not be discussed, but it will be understood that similar looking lines in Figs. 19-22 will have the features discussed herein. The discontinuous bond patterns may be positioned on a landing component. The landing component, as mentioned above, may be an outer cover nonwoven material, a discrete, nonwoven landing zone, or a non-extensible front belt comprising a nonwoven material. The landing component may be configured to receive and hold hooks positioned on tape tabs of fasteners 46. In some instances, the landing component may be positioned in the back waist region and the tape tabs comprising hooks may be positioned in the front waist region if the absorbent article fastens front to back. In other instances, the discontinuous bond patterns may be positioned on other absorbent article components, or on nonwoven materials, for example.

Ellipse Discontinuous Bond Pattern

Fig. 23 is an example discontinuous bond pattern 400 for landing components of absorbent articles, such as outer cover nonwoven materials, discrete landing zones, discrete, non-elasticized front belts, and/or other nonwoven materials or components. The discontinuous bond pattern is optimized for reliable fastening and is configured to receive hooks of a tape tab. The discontinuous bond pattern may also be used for non-landing zone components, such as topsheets, secondary topsheets, portions of an outer cover nonwoven material not configured to receive hooks, ears, side panels, leg cuffs, and/or waistbands, for example. The discontinuous bond pattern 400 may have a bond area in the range of about 8% to about 30%, about 10% to about 25%, about 12% to about 23%, about 14% to about 20%, for example. Bond areas are measured according to the Repeat Unit/Bond Areas Measurement Test herein.

Referring again to Fig. 23, the discontinuous bond pattern 400 may comprise a first plurality of first discontinuous elements 402 forming a first discontinuous ellipse 404 and a second plurality of second discontinuous elements 406 forming a second discontinuous ellipse 408. The second discontinuous ellipse 408 may surround, or at least partially surround, the first discontinuous ellipse 404. Only two discontinuous ellipses may be provided in a repeat unit 401. In other instances, the discontinuous bond pattern 400 may comprise a third plurality of third discontinuous elements 410 forming a third discontinuous ellipse 412. The third discontinuous ellipse 412 may surround, or at least partially surround, the second discontinuous ellipse 408. Only three discontinuous ellipses may be provided in a repeat unit 401. In other instances, the discontinuous bond pattern may also comprise a fourth plurality of fourth discontinuous elements forming a fourth discontinuous ellipse. The fourth discontinuous ellipse may surround, or at least partially surround, the third discontinuous ellipse.

Axis 414 may or may not be generally parallel to the central longitudinal axis 50 (see Fig. 1) and axis 416 may or may not be generally parallel to the central lateral axis 48 (see Fig. 1). In some instances, axis 414 may be angled with respect to the central longitudinal axis 50, such as angled in the range of about 0.5 degrees to about 20 degrees, or about 1 degree to about 15 degrees, for example. This angling may reduce wear on bonding rolls comprising the discontinuous bond patterns. Axis 414 and 416 may be the same as described here in Figs. 24 and 25.

Figs. 24 and 25 are example discontinuous bond patterns 400’ and 400”, respectively, for landing components of absorbent articles, such as outer cover nonwoven materials, discrete landing zones, and/or discrete, non-elasticized front belts, and/or other nonwoven materials or components. In Figs. 24 and 25 only a first discontinuous ellipse 404 and a second discontinuous ellipse 408 are provided, similar to that described above. In Fig. 25 a plurality of dots 420 are surrounded by the first discontinuous ellipse 404.

Although ellipses are shown as an example, other shapes may also be used, such as stars, squares, rectangles, triangles, trapezoids, clouds, for example.

Nonwoven Materials or Absorbent Articles with Nonwoven Materials

Absorbent articles may comprise the one or more nonwoven materials comprising the discontinuous bond patterns (any shown or described herein). The nonwoven materials may not act as landing components in the absorbent articles, such as a topsheet, waistband, and/or leg cuff, for example. In other instances, nonwoven materials outside of the context of absorbent articles may comprise the discontinuous bond patterns (any shown or described herein).

Repeat Unit Measurements

The various repeat units of the landing components may have certain characteristics, such as repeat unit area (overall X-Y plane area of the repeat unit), repeat unit width, and repeat unit length, for example. Absorbent articles comprising landing components comprising a repeating pattern of bonds having a plurality of repeat units may have certain characteristics of the repeat units. Those characteristics are discussed below.

Repeat Unit Area-Landing Components

All of, or a majority of, individual repeat units in a repeating pattern of bonds on landing components of absorbent articles may have a repeat unit area in the range of about 25 mm ² to about 400 mm ² , about 40 mm ² to about 300 mm ² , about 50 mm ² to about 275 mm ² , about 50 mm ² to about 250 mm ² , about 50 mm ² to about 225 mm ² , about 75 mm ² to about 200 mm ² , about 75 mm ² to about 100 mm ² , about 150 mm ² to about 225 mm ² , about 175 mm ² to about 200 mm ² , about 25 mm ² to about 125 mm ² , about 25 mm ² to about 100 mm ² , about 25 mm ² to about 75 mm ² , about 35 mm ² to about 65 mm ² , about 40 mm ² to about 60 mm ² , about 45 mm ² to about 55 mm ² , about 47 mm ² , about 48mm ² , or about 49 mm ² , specifically reciting all 0.1 mm ² increments within the specified ranges and all ranges formed therein or thereby. Repeat unit areas are measured according to the Repeat Unit/Bond Area Measurement Test herein.

Repeat Unit Width-Landing Components

All of, or a majority of, the individual repeat units in a repeating pattern of bonds on a landing component of an absorbent article may have a repeat unit width in the range of about 5 mm to about 75 mm, about 5 mm to about 50 mm, about 8 mm to about 40 mm, about 10 mm to about 30 mm, about 10 mm to about 25 mm, about 10 mm to about 20 mm, about 10 mm to about 18 mm, about 10 mm to about 15 mm, about 15 mm, about 11, about 12, or about 13 mm, specifically reciting all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby. Repeat unit widths are measured according to the Repeat Unit/Bond Area Measurement Test herein.

Repeat Unit Length-Landing Components

All of, or a majority of, the individual repeat units in a repeating pattern of bonds on a landing components of an absorbent article may have a repeat unit length in the range of about 2 mm to about 75 mm, about 2 mm to about 50 mm, about 3 mm to about 40 mm, about 3 mm to about 30 mm, about 3 to about 25, about 3 mm to about 20 mm, about 3 mm to about 10 mm, about 10 mm to about 20mm, about 17 mm, about 6 mm, about 7 mm, about 1 to about 10, about 2 mm to about 8mm, about 2 mm to about 6 mm, about 3 mm to about 5 mm, or about 4 mm, specifically reciting all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby. Repeat unit lengths are measured according to the Repeat Unit/Bond Area Measurement Test herein.

Fuzz

There is a sweet spot for repeat unit size on landing components of absorbent articles. A fuzzy looking landing component may not have a premium appearance. The fuzz may be caused by the repeat units being too large. If the repeat units are too small, the landing components may not look premium. If the repeat units are too large, the landing components may also not look premium as there are too few repeat units on a landing component. It may be desirable to have large enough repeat units to look premium, but not have the repeat units be so large that there is a lot of un-bonded open space that could create fuzz during consumer usage. The smaller the repeat unit, the lower the chance of fuzzing in un-bonded open spaces. In a landing component context, there may be a need to balance premium appearance with repeat unit size, while still maintaining the repeat unit size small enough to reduce fuzzing and small enough to have fastening strength for being engaged by hooks. Another aspect of premium appearance may be the ability for consumer to see areas that are un-bonded. It is possible to fill in these un-bonded areas with bonds (to reduce fuzz), but it may reduce the premium appearance.

Materials

The discrete landing zones, the discrete non-elasticized front belts, the outer cover nonwoven materials, or other nonwoven materials or components comprising the discontinuous bond patterns of the present disclosure may comprise any suitable nonwoven materials and/or other materials. Some examples are carded nonwoven materials, air-laid nonwoven materials, wet-laid nonwoven materials, air-through spun nonwovens, spunbond nonwoven materials, spunbond high loft materials (e.g., spunbond with at least one layer of crimped fibers), and/or combinations thereof. The nonwoven materials may comprise natural fibers, such as cotton and/or other bio based materials or resins. The nonwoven materials may be embossed, ultrasonically embossed, hydroentangled, and/or apertured for example. The nonwoven materials may have discontinuous bonds and three-dimensional features or discontinuous bonds, apertures, and three-dimensional features, for example.

The discrete landing zones, the discrete non-elasticized front belts, the outer cover nonwoven materials, or other nonwoven materials or components comprising the discontinuous bond patterns of the present disclosure may comprise PE/PP bicomponent fiber spunbond nonwoven webs. Other suitable nonwoven webs may comprise spunbond webs comprising side- by-side crimped fibers (e.g., PE/PP or PP/PP) that are bonded via calendar (thermal point) bonding or through-air bonding. Other suitable nonwoven webs may comprise carded, through-air bonded or resin bonded (highloft) nonwovens comprising PE/PP or PE/PET fibers. The nonwoven webs may also comprise PE/PLA or PE/Polyamide bicomponent fibers. The nonwoven webs may comprise nanofibers or meltblown fibers, optionally with other fibers. In some instances, multiple layer webs may be desired over a single layer webs (even at the same basis weight) due to increased uniformity/opacity and the ability to combine webs having different properties. For example, an extensible spunbond nonwoven carrier layer may be combined with a soft, highloft nonwoven (spunbond or carded) to create a nonwoven web that is both soft and strong. The layers may have the same or different surface energy. The layers may have different permeability/capillarity.

Fibers of the discrete landing zones, the discrete non-elasticized front belts, the outer cover nonwoven materials, or other nonwoven components comprising the discontinuous bond patterns may comprise any suitable thermoplastic polymers. Example thermoplastic polymers are polymers that melt and then, upon cooling, crystallize or harden, but that may be re-melted upon further heating.

The thermoplastic polymers may be derived from any suitable material including renewable resources (including bio-based and recycled materials), fossil minerals and oils, and/or biodegradeable materials. Some suitable examples of thermoplastic polymers include polyolefins, polyesters, polyamides, copolymers thereof, and combinations thereof. Polypropylene and/or polypropylene copolymers, including atactic polypropylene; isotactic polypropylene, syndiotactic polypropylene, and combination thereof may also be used.

The thermoplastic polymer component may be a single polymer species or a blend of two or more thermoplastic polymers e.g., two different polypropylene resins. As an example, fibers of a first nonwoven layer of discrete landing zones, discrete, non-elasticized front belts, an outer cover nonwoven material, or other nonwoven components comprising the discontinuous bond patterns may comprise polymers such as polypropylene and blends of polypropylene and polyethylene, while a second nonwoven layer of the discrete landing zones, the discrete, non-elasticized front belts, the outer cover nonwoven, or other nonwoven components comprising the discontinuous bond patterns may comprise fibers selected from polypropylene, polypropylene/polyethylene blends, and polyethylene/polyethylene terephthalate blends. In some forms, a second nonwoven layer may comprise fibers selected from cellulose rayon, cotton, other hydrophilic fiber materials, or combinations thereof.

The fibers of the discrete landing zones, the discrete, non-elasticized front belts, the outer cover nonwoven materials, or other nonwoven components comprising the discontinuous bond patterns may comprise monocomponent fibers, bi-component fibers, and/or bi-constituent fibers, tri-lobal fibers, round fibers or non-round fibers (e.g., capillary channel fibers), and may have major cross-sectional dimensions (e.g., diameter for round fibers) ranging from about 0.1 microns to about 500 microns, about 5 microns to about 250 microns, about 10 microns to about 100 microns, or about 12 microns to about 25 micron, specifically reciting all 0.1 micron increments within the specified ranges and all ranges formed therein or thereby, for example. The fibers may also comprise a mixture of different fiber types, differing in such features as chemistry (e.g., polyethylene and polypropylene), components (mono- and bi-), denier (micro denier and >2 denier), shape (i.e., capillary and round) and the like. The fibers may range from about 0.1 denier to about 100 denier.

As used herein, the term“monocomponent fiber(s)” refers to a fiber formed from one extruder using one or more polymers. This is not meant to exclude fibers formed from one polymer to which small amounts of additives have been added for coloration, antistatic properties, lubrication, hydrophilicity, etc.

As used herein, the term“bi-component fiber(s)” refers to fibers which have been formed from at least two different polymers extruded from separate extruders but spun together to form one fiber. Bi-component fibers are also sometimes referred to as conjugate fibers or multicomponent fibers. The polymers are arranged in substantially constantly positioned distinct zones across the cross-section of the bi-component fibers and extend continuously along the length of the bi-component fibers. The configuration of such a bi-component fiber may be, for example, a sheath/core arrangement where one polymer is surrounded by another polymer, or may be a side- by-side arrangement, a pie arrangement, or an islands-in-the-sea arrangement. Some specific examples of fibers which may be used in a nonwoven layer comprise polyethylene/polypropylene side-by-side bi-component fibers. Another example is a polypropylene/polyethylene bi component fiber where the polyethylene is configured as a sheath and the polypropylene is configured as a core within the sheath. Eccentric sheath/core configurations for any two materials are also within the scope of the present disclosure. Still another example is a polypropylene/polypropylene bi-component fiber where two different propylene polymers are configured in a side-by-side configuration. Additionally, forms are contemplated where the fibers of a nonwoven layer are crimped.

Bi-component fibers may comprise two different resins, e.g. a first polypropylene resin and a second polypropylene resin. The resins may have different melt flow rates, molecular weights, or molecular weight distributions.

As used herein, the term“bi-constituent fiber(s)” refers to fibers which have been formed from at least two polymers extruded from the same extruder as a blend. Bi-constituent fibers do not have the various polymer components arranged in relatively constantly positioned distinct zones across the cross-sectional area of the fiber and the various polymers are usually not continuous along the entire length of the fiber, instead usually forming fibrils which start and end at random. Bi-constituent fibers are sometimes also referred to as multi-constituent fibers. In other examples, a bi-component fiber may comprise multiconstituent components. As used herein, the term“non-round fiber(s)” describes fibers having a non-round cross- section, and includes“shaped fibers” and“capillary channel fibers.” Such fibers may be solid or hollow, and they may be tri-lobal, delta-shaped, and may be fibers having capillary channels on their outer surfaces. The capillary channels may be of various cross-sectional shapes such as“U- shaped”,“H-shaped”,“C-shaped” and“V-shaped”. One practical capillary channel fiber is T-401, designated as 4DG fiber available from Fiber Innovation Technologies, Johnson City, TN. T-401 fiber is a polyethylene terephthalate (PET polyester).

The fibers may comprise Ti02 as an opacifier, Erucamide for softness, and/or color melt additives for tinting. The fibers may also comprise other melt additives known to those of skill in the art.

Examples/Combinations :

A. An absorbent article comprising:

a lateral axis;

a front waist region on a first side of the lateral axis;

a back waist region on a second side of the lateral axis;

a liquid permeable topsheet;

a liquid impermeable backsheet;

an absorbent core positioned at least partially intermediate the topsheet and the backsheet; a landing component comprising a nonwoven material in the front waist region; and the landing component comprising a discontinuous bond pattern;

wherein the discontinuous bond pattern forms a bond area in the range of about 10% to about 20% of the repeat unit, according to the Repeat Unit/Bond Area Measurement Test;

wherein the discontinuous bond pattern comprises:

a first plurality of first discontinuous elements forming a first discontinuous ellipse;

a second plurality of second discontinuous elements forming a second discontinuous ellipse, wherein the second discontinuous ellipse surrounds the first discontinuous ellipse; and

a third plurality of third discontinuous elements forming a third discontinuous ellipse, wherein the third discontinuous ellipse surrounds the second discontinuous ellipse. B. The absorbent article of Paragraph A, wherein the discontinuous bond pattern comprises: a fourth plurality of fourth discontinuous elements forming a fourth discontinuous ellipse, wherein the fourth discontinuous ellipse surrounds the third discontinuous ellipse.

C. An absorbent article comprising:

a lateral axis;

a front waist region on a first side of the lateral axis;

a back waist region on a second side of the lateral axis;

a liquid permeable topsheet;

a liquid impermeable backsheet;

an absorbent core positioned at least partially intermediate the topsheet and the backsheet; a landing component comprising a nonwoven material in the front waist region; and the landing component comprising a discontinuous bond pattern;

wherein the discontinuous bond pattern forms a bond area in the range of about 10% to about 20% of the repeat unit, according to the Repeat Unit/Bond Area Measurement Test;

wherein the discontinuous bond pattern comprises:

a first plurality of first discontinuous elements forming a first discontinuous ellipse; and

a second plurality of second discontinuous elements forming a second discontinuous ellipse, wherein the second discontinuous ellipse surrounds the first discontinuous ellipse.

D. A landing component for an absorbent article, the landing component comprising:

a nonwoven material; and

the nonwoven material comprising a discontinuous bond pattern;

wherein the discontinuous bond pattern forms a bond area in the range of about 10% to about 20%, according to the Repeat Unit/Bond Area Measurement Test;

wherein the discontinuous bond pattern comprises:

a first plurality of first discontinuous elements forming a first discontinuous line; a second plurality of second discontinuous elements forming a second discontinuous line; and

a third plurality of third discontinuous elements positioned intermediate the first discontinuous line and the second discontinuous line, wherein the plurality of third discontinuous elements form a third discontinuous line that extends in a direction transverse to the first and second discontinuous lines. E. A nonwoven material comprising:

a discontinuous bond pattern;

wherein the discontinuous bond pattern forms a bond area in the range of about 10% to about 20%, according to the Repeat Unit/Bond Area Measurement Test;

wherein the discontinuous bond pattern comprises:

a first plurality of first discontinuous elements forming a first discontinuous line; a second plurality of second discontinuous elements forming a second discontinuous line; and

a third plurality of third discontinuous elements positioned intermediate the first discontinuous line and the second discontinuous line, wherein the plurality of third discontinuous elements form a third discontinuous line that extends in a direction transverse to the first and second discontinuous lines.

F. An absorbent article comprising:

a nonwoven material;

the nonwoven material comprising a discontinuous bond pattern;

wherein the discontinuous bond pattern forms a bond area in the range of about 10% to about 20%, according to the Repeat Unit/Bond Area Measurement Test;

wherein the discontinuous bond pattern comprises:

a first plurality of first discontinuous elements forming a first discontinuous line; a second plurality of second discontinuous elements forming a second discontinuous line; and

a third plurality of third discontinuous elements positioned intermediate the first discontinuous line and the second discontinuous line, wherein the plurality of third discontinuous elements form a third discontinuous line that extends in a direction transverse to the first and second discontinuous lines.

G. An absorbent article comprising:

a lateral axis;

a front waist region on a first side of the lateral axis;

a back waist region on a second side of the lateral axis;

a liquid permeable topsheet;

a liquid impermeable backsheet;

an absorbent core positioned at least partially intermediate the topsheet and the backsheet; a discrete landing zone or a discrete, non-elasticized front belt in the front waist region; and

the discrete landing zone or the discrete, non-elasticized front belt comprising a discontinuous bond pattern;

wherein the discontinuous bond pattern forms a bond area in the range of about 10% to about 20%, according to the Repeat Unit/Bond Area Measurement Test;

wherein the discontinuous bond pattern comprises:

a first plurality of first discontinuous elements forming a first discontinuous line; a second plurality of second discontinuous elements forming a second discontinuous line; and

a third plurality of third discontinuous elements positioned intermediate the first discontinuous line and the second discontinuous line, wherein the plurality of third discontinuous elements form a third discontinuous line that extends in a direction transverse to the first and second discontinuous lines;

wherein the first and second discontinuous lines are longer than the third discontinuous line.

H. The absorbent article of Claim G, wherein the discrete landing zone or the discrete, non- elasticized front belt comprise a nonwoven material.

I. The absorbent article of Claim H, wherein the nonwoven material comprises a side-by- side multi-component fibers comprising a first polypropylene component and a second, different polypropylene component.

J. The absorbent article of Claim H, wherein the nonwoven material comprises a side-by- side multi-component fibers comprising a first polyethylene component and a second

polypropylene component.

Test Methods

Repeat Unit/Bond Area Measurement Test

An absorbent article specimen is taped to a rigid flat surface in a planar configuration with the test region, such as the outer cover nonwoven material, the discrete landing zone, the discrete, non-elasticized front belt, or other nonwoven component, for example, comprising the discontinuous bond pattern comprising a plurality of individual repeat units facing upward. The absorbent article is taped in such way as to avoid introducing distortions of the discontinuous bond pattern due to the extent of longitudinal and lateral extension of the absorbent article. Any absorbent article(s) being tested are conditioned at 23 °C ± 2 C° and 50% ± 2% relative humidity for 2 hours prior to testing. For the purposes of this method, all patterns and distances are taken to be based on the projection of the bond pattern onto a two-dimensional plane.

A single repeat unit (hereafter“SRU”) (for subsequent dimensional measurement) within the test region comprising the discontinuous bond pattern comprising the plurality of repeating units is defined as follows. An arbitrary bond, print, or aperture is identified, referred to hereafter as the“chosen point” (hereafter“CP”). Any other bond in the test region recognized to be in an equivalent position based on the translational symmetry of the repeat units is referred to as an “equivalent point” (hereafter“EP”). The SRU is defined as the set of points that are closer (via Euclidean distance) to the center of the CP than to the center of any other EP in the test region. The SRU identified for measurement must not touch the edge of the test region. After finding all points within the SRU, if it is found that the SRU touches the edge of the test region, this procedure is repeated with an alternative CP. The process is repeated until a SRU that does not touch the edge of the test region is identified.

One approach to determining the set of points of a SRU is based on identifying a polygonal boundary. Referring to Figs. 26 and 27, the boundary of the SRU is the convex polygon formed by the intersection of line segments that immediately border the topsheet region containing the CP. The line segments are identified from lines drawn perpendicular to the midpoint of lines connecting the center of the CP to the center of all neighboring and nearby EP.

To calculate the Bond Area percent of a repeat unit the interior area of the SRU is measured and recorded. The boundary perimeters of all of the individual bond pattern elements, or portions thereof, located within the SRU are identified. The areas of the identified bond pattern elements, or portions thereof, that are located within the SRU are measured and recorded. The Percent Bond Area is then calculated according to the following equation:

Sum of Bond Pattern Element Areas

Bond Area = x 100%

Area of SRU

The Bond Area is recorded to the nearest 1%.

The interior area of the SRU is recorded to the nearest 0.1 mm ² .

Referring to Fig. 28, the SRU length (L) is defined as the feret diameter parallel to the longitudinal axis of the absorbent article, and the SRU width (W) is defined as the feret diameter parallel to the lateral axis of the absorbent article. The feret diameter is the distance between two parallel lines, both of which are tangential to the boundary of the SRU, and is recorded to the nearest 0.1 mm.

The interior area of the SRU is recorded to the nearest 0.1 mm ² .

Repeat this procedure on five separate substantially similar absorbent articles having a region of a discontinuous bond pattern comprising a plurality repeat units that are the same or substantially the same, and report each of the measurements as the average of the five replicates.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as“40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any embodiment disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such embodiment. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present disclosure have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications may be made without departing from the spirit and scope of the present disclosure. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this disclosure.