In general, embodiments of the present disclosure relate to wearable absorbent articles. In particular, embodiments of the present disclosure relate to wearable absorbent articles with bonded and printed fibrous materials.
Wearable absorbent articles are useful for receiving, containing, and absorbing bodily exudates. Many front-fastenable wearable absorbent articles include bonded and printed fibrous materials. For example, such articles can include a hook and loop fastening system made from bonded and printed materials. In such systems, hook portions are provided on fastening ears and a loop portion is formed on the front of the article, so that the back of the article can be secured to the front.
A fibrous landing zone can be used to form the loop portion. It is often desirable to include printed graphics (such as letters, character images, and numbers) on the fibrous landing zone. However, for purposes of structural integrity and fastening performance, it is necessary to provide spaced apart bonded areas throughout the fibrous landing zone. Unfortunately, the presence of bonded areas on a fibrous landing zone makes it more difficult to visually discern printed graphics on the fibrous landing zone.
The present disclosure includes front-fastenable wearable absorbent articles with fibrous landing zones having areas printed with graphics and bond patterns overlaying the printed areas, wherein the printed areas and the bond patterns are configured to allow the graphics to be readily visibly discernible.
Throughout the present disclosure, landing zones are used to describe and illustrate various embodiments. However, it is contemplated that embodiments of the present disclosure are not limited to landing zones, but can be similarly applied to other bonded and printed fibrous materials in wearable absorbent articles. For example, part, or parts, or all of a topsheet, a backsheet, a side ear, a side panel, a waistband, and/or a leg band of a wearable absorbent article could be configured with printed graphics and a bond pattern, according to embodiments of the present disclosure.
In embodiments throughout the present disclosure, a fibrous landing zone can be constructed of any fibrous materials in any manner known in the art. Fibrous materials can be made from animal fibers, plant fibers, mineral fibers, synthetic fibers, etc. Fibrous materials can include short fibers, long fibers, continuous fibers, fibers of varying lengths or cross-sectional geometries, or combinations of any of these. Throughout the present disclosure, nonwoven materials are used to describe and illustrate various embodiments of fibrous materials. However, it is contemplated that embodiments of the present disclosure are not limited to nonwoven materials, but can be similarly applied to a wide variety of fibrous materials, such as those described above, as will be understood by one of skill in the art.
The term “nonwoven material” refers to a sheet-like structure (e.g. web) of fibers (sometimes referred to as filaments) that are interlaid in a non-uniform, irregular, or random manner. A nonwoven material can be a single layer structure or a multiple layer structure. A nonwoven material can also be joined to another material, such as a film, to form a laminate. A nonwoven material can be made from various natural and/or synthetic materials. Exemplary natural materials include cellulosic fibers, such as cotton, jute, pulp, and the like; and also can include reprocessed cellulosic fibers like rayon or viscose. Natural fibers for a nonwoven material can be prepared using various processes such as carding, etc. Exemplary synthetic materials include but are not limited to synthetic thermoplastic polymers that are known to form fibers, which include, but are not limited to, polyolefins, e.g., polyethylene, polypropylene, polybutylene and the like; polyamides, e.g., nylon 6, nylon 6/6, nylon 10, nylon 12 and the like; polyesters, e.g., polyethylene terephthalate, polybutylene terephthalate, polylactic acid and the like; polycarbonate; polystyrene; thermoplastic elastomers; vinyl polymers; polyurethane; and blends and copolymers thereof.
Also, in embodiments throughout the present disclosure, graphics can be printed on a nonwoven landing zone in any manner known in the art. As a first example, graphics can be printed on the fibers on the outside surface of the nonwoven layer of the landing zone; that is, the surface that is exposed, for receiving the fastening ears. As a second example, graphics can be printed on the fibers on the inside surface of the nonwoven layer of the landing zone; that is, the surface that is opposite from the outside surface. As a third example, graphics can be printed on an underlying substrate; that is, a substrate that lies under the nonwoven layer of the landing zone and thus faces the inside surface. Graphics can also be printed on a nonwoven landing zone using various combinations of any of these methods, or any other method known in the art.
Further, in embodiments throughout the present disclosure, a bond pattern can be applied to a nonwoven landing zone in any manner known in the art. As examples, a bond pattern can be applied by using heat, pressure, ultrasonic bonding, adhesive, other bonding means known in the art, or combinations of any of these. For instance, a nonwoven web can be bonded by passing the nonwoven web through a nip formed by a heated calendar roll (with a plurality of raised lands) and another roll, such that the lands form bond areas on the nonwoven web.
The nonwoven web can be of different levels of opacity depending on the type of fibers, resins, and or the basis weight of the nonwoven used to make a nonwoven landing zone (opacity is typically measured by a Reflectance Spectrophotometer at 45 degrees). Opacity levels for nonwovens are known in the art to be sensitive, but not limited to the material density, thickness, and the degree of pigmentation used (Titaniumdioxide, TiO2). For example a high degree of nonwoven web opacity indicates a high degree of obscuring the background or an artwork behind it. Most common for hygiene nonwovens is the use of TiO2 at different levels for desired fiber pigmentation.
The landing zone 120 has a machine direction (MD) 122 and a cross direction (CD) 126, which are defined by the process for manufacturing the nonwoven material. In various embodiments, the fibers of the nonwoven material may or may not be configured to have an MD or CD directionality. The landing zone also has an overall longitudinal length 126 and an overall lateral width 128.
The printed area 130 has an overall shape that is rectangular, although in various embodiments, the printed area can have an overall shape that is a different shape. The printed area 130 has an overall longitudinal length 136 and an overall lateral width 138. The printed area 130 includes various graphic images, such as letters 140, a character image 150, and a number 160. As used herein a graphic image can also include other recognizable images (such as a plant, a car, etc.) and geometric shapes, such as circles, squares, rectangles, triangles, stars, etc. A printed area of a nonwoven landing zone can also include other graphics of one or more colors. In the embodiment of
However, the nonwoven landing zone 120 can be printed on the outside surface or in various alternate ways, as will be understood by one of ordinary skill in the art.
The printed area 130 can include a background color and the character image 150 can include a character color. A background color surrounds at least a substantial portion of a character image and may or may not completely surround the character image. A printed area can include other colors in addition to a background color. In various embodiments, a background color can partially, or substantially, or completely fill a printed area. A character color fills at least a substantial portion of a character image and may or may not completely fill the character image. A character image can include other colors in addition to a character color.
In various embodiments, a background color can be different from, similar to, or the same as a character color. Tables 1, 2, and 3, below, provide six exemplary embodiments of
In the six examples described in Tables 1-3, colors can be obtained from Adobe Photoshop 10.0.1 (copyright 1990-2007, Adobe Systems Incorporated) using the Color Picker tool, which reports CIE L*a*b* colors based on the 1976 Commission Internationale d'Eclairage standard. For reference, Adobe Photoshop's CIE L*a*b* scales are 0 to 100 for L*, −128 to 127 for a*, and −128 to 127 for b*. The reported colors and ranges can represent target colors from an artwork file to be printed.
In these six examples, the differences in the lightness values between the background color and the character color ranged from 2-20. However, it is contemplated that a nonwoven landing zone with a printed area and a character image can have a background color and a character color with differences in CIELAB lightness (L) values of at least 10, at least 20, at least 30, at least 40, at least 50, or at least 60, or any integer value between these values. These differences in lightness can be determined by taking the absolute value of: the L value of the character color minus the L value of the background color. Without wishing to be bound by this theory, it is believed that differences in lightness between a background color and a character color allow a character image to be more readily seen in a printed area of a nonwoven landing zone.
In these six examples, the differences in the CIELAB a values between the background color and the character color ranged from 13-69. However, it is contemplated that a nonwoven landing zone with a printed area and a character image can have a background color and a character color with differences in CIELAB a values of at least 10, at least 20, at least 30, at least 40, at least 50, or at least 60, at least 70, at least 80, or any integer value between these values. These differences in a color can be determined by taking the absolute value of: the a value of the character color minus the a value of the background color. Also, in these six examples, the differences in the CIELAB b values between the background color and the character color ranged from 4-96. These differences in b color can be determined by taking the absolute value of: the b value of the character color minus the a value of the background color. However, it is contemplated that a nonwoven landing zone with a printed area and a character image can have a background color and a character color with differences in CIELAB b values of at least 10, at least 20, at least 30, at least 40, at least 50, or at least 60, at least 70, at least 80, at least 90, at least 100, or any integer value between these values.
Each of the letters 140 has a character width 142 and an overall height 146. All of the disclosure that relates to the character width of the letters can be similarly applied to the character width of numbers. The character image 150 has an overall height 156, measured longitudinally across the tallest portion of the character image, and an overall width 158, measured laterally across the widest portion of the character image. As used herein, the overall height and the overall width are considered major dimensions of the character image. The character image 150 is outlined by a contour line 155, which surrounds the character image 150, in order to highlight the character image 150 with respect to any background color or artwork in the printed area 130 and thus make the character image 150 more easily visible. In the embodiment of
The dimensions of these printed graphics can be selected in relation to the dimensions of bond lines in a nonwoven bonding pattern applied to the nonwoven landing zone 120. In particular, the character width 142 of the letters 140, the width of the contour line 155, and the overall lengths, widths, and heights of images, letters, and numbers can be selected, in relation to dimensions of the bond lines, as described below.
A bonded and printed fibrous material can be configured such that elements in the printed area, such as the overall width of a character image, the overall height of letters or numbers, the overall height of a character image, the contour width, and/or the character width, can be sized in relation to aspects of a bond pattern, such as the pitch of bond lines, the amplitude of bond lines, the wavelength of bond lines, and/or the width of bond lines, as described herein. The aspects of the bond pattern are defined in the description of the embodiment of
In the embodiment of
In the embodiment of
In the embodiment of
In the embodiment of
In the embodiment of
The bond pattern 670 includes a plurality of bond lines 671, 672, 673, 674, 675, and 676. In
A bond pattern with a number of bond lines having a wavy shape is considered more useful than a bond pattern with a series of parallel bond lines having a straight line shape because straight lines would be unlikely to bond nonwoven fibers in some orientations. For example, a series of parallel bond lines oriented in the cross-direction on a nonwoven material would be unlikely to catch nonwoven fibers primarily oriented in the cross-direction and disposed between the bond lines. As a result, these unbonded fibers would offer reduced strength loops and thus a hook and loop fastening system with reduced performance. Thus, embodiments of the present disclosure contemplate bond patterns with a number of bond lines having a wavy shape. As used herein, the term “wavy” is intended to mean a non-linear shape that has at least some minimal amplitude along its length; that is, a wavy shape deviates from its overall course by more than one thickness of its pathway. In various embodiments, a wavy shape can be continuously curved, can be partially curved and partially linear, or can be formed from a series of connected linear segments, such as a zig-zag pattern.
The bond line 671 is a continuous wavy line formed by a repeating pattern of identical waves. However, in various embodiments, a bond line can be a discontinuous line, or an effective line formed by a number of lines segments, or an effective line formed by a series of spaced apart bond areas. Also, in some embodiments, the waves may not be identical. The present disclosure contemplates that each wave in each bond line can vary in any way described herein.
In the bond pattern 670, the waves of each of the bond lines 671-676 are formed by an alternating series of peaks and troughs. In the illustrated portion of the pattern 670, the bond line 671 includes a first trough 671T-1 followed by a first peak 671P-1 followed by a second trough 671T-2 followed by a second peak 671P-2, and so on. The bond line 671 has a constant wave amplitude 684 measured longitudinally from top of peak to bottom of trough and a constant wavelength 686 measured laterally from a trough to an adjacent trough (or from a peak to an adjacent peak). In alternate embodiments, a bond line can have a varying wave amplitude and/or wavelength. The bond line 671 is continuously curved with an inside radius 683 on each peak and trough. In the embodiment of
The bond line 672 is configured in the same way as the bond line 671. Thus, the bond line 672 includes a first trough 672T-1, a first peak 672P-1, a second trough 672T-2, and a second peak 671P-2. The bond line 672 also has the constant amplitude 684 and the constant wavelength 686. In the lateral direction, the bond line 672 is in phase with the bond line 671, such that the peaks of the bond line 672 are aligned with the peaks of the bond line 671. The troughs of the bond lines 671 and 672 are similarly aligned. However, in various embodiments, one or more bond lines can be out of phase.
Line V1 is a longitudinally oriented reference line drawn through the bottom of the first trough on each of the bond lines 671 through 676. Line V2 is a longitudinally oriented reference line drawn through the second trough on each of the bond lines 671 through 676. Since the bond lines 671 and 672 are in phase, the first trough 671T-1 and the first trough 672T-1 are both aligned on line V1. Since the bond lines 671 and 672 have the same wavelength 686, the second troughs 671T-2 and 672T-2 are aligned on line V2. Each of the other bond lines 673 through 676 is aligned in the same way with bond lines 671 and 672, as well as with each other.
The bond line 671 has a constant bond line width 682. Each of the other bond lines 672 through 676 has the same constant bond width. However, in some embodiments, a bond line width can vary along a bond line or from one bond line to another.
The bond line 672 is longitudinally offset from the bond line 671 by a pitch 688 measured longitudinally from top of peak on bond line 671 to top of peak on bond line 672 (or bottom of trough to bottom of trough, respectively). Each of the other bond lines 673 through 676 is longitudinally offset from the adjacent bond line by the same pitch 688 to create a regular array of bond lines in the bond pattern 670. As a result, all of the bond lines 671-676 are non-intersecting with respect to each other. In some alternate embodiments, a bond pattern can include bond lines offset from each other with varying pitches.
Line H1 is a laterally oriented reference line drawn along the bottoms of the troughs on the bond line 671. Line H2 is a laterally oriented reference line drawn along the tops of the peaks on the bond line 671. In the embodiment of
In a bond pattern, the bond line width, the wave amplitude, the wavelength, and the pitch together determine the percent area that is bonded (and the percent area that is unbonded).
In various embodiments, it may be beneficial to the visual appearance of a printed area overlaid with a bond pattern, to reduce the bond line width while maintaining a target percent bonded area. In order to do so, the pitch of the bond pattern can be reduced, to control the percent bonded area. Without wishing to be bound by this theory, the present disclosure contemplates that a bond pattern with a reduced bond line width and a reduced pitch offers a more homogeneous appearance that is visually pleasing and allows images on the printed area to be more readily visibly discernible from the bond pattern.
For example, a bond pattern can have a bond line width of less than 0.8 millimeters, but a reduced pitch, in order to maintain a bonded area of at least 20%. As another example, a bond pattern can have a bond line width of less than 0.6 millimeters, but a reduced pitch, in order to maintain a bonded area of at least 20%. As a further example, a bond pattern can have a bond line width of less than 0.4 millimeters, but a reduced pitch, in order to maintain a bonded area of at least 20%. As still a further example, a bond pattern can have a bond line width of less than 0.2 millimeters, but a reduced pitch, in order to maintain a bonded area of at least 20%. Alternatively, these examples can also be implemented with other target percent bonded areas, such as targets of 15% or 25%, or any integer value for a percent between these two values.
However, there are practical lower limits to bond line width and bond pattern pitch. If a bond line width is reduced to a very small dimension (e.g. to about 0.1 millimeter or less), then some bonding processes may begin tearing or cutting nonwoven fibers rather than properly bonding them. Also, if a pitch of a bond pattern is reduced to a very small dimension (e.g. to about 1 millimeter or less), then there may be insufficient unbonded nonwoven fibers for forming loops, resulting in a need for much larger (and more expensive hook areas) or resulting in a hook and loop fastening system with reduced performance. These considerations will be understood by one of ordinary skill in the art.
In a particular embodiment, a bond pattern can be configured in the same way as the bond pattern 670, with the following dimensions: a constant bond line width of 0.6 millimeters, a constant wave amplitude of 3.4 millimeters, a constant wavelength of 24.42 millimeters, and a constant pitch of 3.4 millimeters, resulting in a bonded area of approximately 18%. The present disclosure contemplates variations of this particular embodiment wherein any of the dimensions described above can be varied independent from the others. This particular embodiment can be varied as described below.
One or more bond lines in a bond pattern can have a constant bond line width that can be less than 0.2 millimeters, or 0.2 millimeters, or 0.3 millimeters, or 0.4 millimeters, or 0.5 millimeters, or 0.6 millimeters, or 0.7 millimeters, or 0.8 millimeters, or 0.9 millimeters, or 1.0 millimeters, or 1.1 millimeters, or 1.2 millimeters, or 1.3 millimeters, or 1.4 millimeters, or 1.5 millimeters, or 1.6 millimeters, or 1.7 millimeters, or 1.8 millimeters, or 1.9 millimeters, or 2.0 millimeters, or greater than 2.0 millimeters, or any width between any of these specific values. Alternatively, a bond line width can vary between any of the values described above.
One or more bond lines in a bond pattern can have a constant wave amplitude that can be less than 2.0 millimeters, or 2.0 millimeters, or 2.5 millimeters, or 3.0 millimeters, or 3.5 millimeters, or 4.0 millimeters, or 4.5 millimeters, or 5.0 millimeters, or 5.5 millimeters, or 6.0 millimeters, or 6.5 millimeters, or 7.0 millimeters, or greater than 7.0 millimeters, or any value between any of these specific values, in increments of 0.1 millimeters. Alternatively, a wave amplitude can vary between any of the values described above. In various embodiments, it may be beneficial to the visual appearance of a printed area overlaid with a bond pattern to have a wave amplitude that is low (e.g. less than 10 millimeters) but non-zero. Without wishing to be bound by this theory, the present disclosure contemplates that a bond pattern having a wave amplitude that is low is visually pleasing, but still avoids the difficulties presented by bond lines having a straight line shape, as discussed above.
One or more bond lines in a bond pattern can have a constant wavelength that can be less than 5 millimeters, or 5 millimeters, or 10 millimeters, or 15 millimeters, or 20 millimeters, or 25 millimeters, or 30 millimeters, or 35 millimeters, or 40 millimeters, or 45 millimeters, or 50 millimeters, or greater than 50 millimeters or any integer value in millimeters between any of these specific values. Alternatively, a wavelength can vary between any of the values described above.
A bond pattern can have bond lines at a constant pitch that can be less than 2.0 millimeters, or 2.0 millimeters, or 2.5 millimeters, or 3.0 millimeters, or 3.5 millimeters, or 4.0 millimeters, or 4.5 millimeters, or 5.0 millimeters, or 5.5 millimeters, or 6.0 millimeters, or 6.5 millimeters, or 7.0 millimeters, or greater than 7.0 millimeters or any value between any of these specific values, in increments of 0.1 millimeters. Alternatively, a bond pattern pitch can vary between any of the values described above.
A bond pattern can result in a bonded area that can be less than 10%, or 10%, or 15%, or 20%, or 30%, or greater than 30%, or any integer value in percent between any of these specific percentages.
In a particular embodiment, the nonwoven landing zone 720 can be configured with the following dimensions: an overall longitudinal length of the landing zone is 35 millimeters, an overall lateral width of the landing zone is 136 millimeters, an overall longitudinal length of the printed area is 25 millimeters, and an overall lateral width of the printed area is 126 millimeters. However, in various embodiments, any of these dimensions case be varied.
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 invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. 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 invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
This application claims the benefit of U.S. provisional patent application 61/180,040 filed May 20, 2009, and the benefit of U.S. provisional patent application 61/223,477 filed Jul. 7, 2009, the substances of which is hereby incorporated by reference.
Number | Date | Country | |
---|---|---|---|
61180040 | May 2009 | US | |
61223477 | Jul 2009 | US |