| Extensible absorbent layer and absorbent article -> Monitor Keywords |
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Extensible absorbent layer and absorbent articleRelated Patent Categories: Surgery, Means And Methods For Collecting Body Fluids Or Waste Material (e.g., Receptacles, Etc.), Absorbent Pad For External Or Internal Application And Supports Therefor (e.g., Catamenial Devices, Diapers, Etc.), Containing Layers Having Differing Absorption Characteristics (e.g., Flow Control, Wicking, Etc.), Needled Or Punched LayerExtensible absorbent layer and absorbent article description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070135787, Extensible absorbent layer and absorbent article. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE INVENTION [0001] The present invention relates to disposable absorbent articles such as sanitary napkins, pantiliners or incontinence pads and absorbent layers used therein. The present invention further relates to a process of manufacturing an absorbent layer or absorbent article. BACKGROUND OF THE INVENTION [0002] Disposable absorbent articles, such as sanitary napkins worn by women, must fulfill numerous requirements in order to be considered satisfactory for use. From the standpoint of the consumer using the disposable absorbent article, efficient absorption and retention of liquid and other discharges from the human body must be provided, and possible soiling of the wearer's body or the wearer's garment should be avoided. In addition, the absorbent article should be comfortable for a user to wear. The absorbent article should therefore be able to individually conform to the shape of the wearer's body, so that the wearer is not hindered by the absorbent article. Ideally, the absorbent article should not be perceived by the wearer at all when worn. On the other hand, the absorbent article should not be too soft and deformable, otherwise bunching, twisting or roping of the absorbent article or lumping of the absorbent layer may occur, when the article is worn. This would seriously deteriorate the performance of the absorbent article and influence negatively the wearing comfort. Furthermore, the absorbent article and especially the absorbent layer must have sufficient structural integrity to withstand the forces exerted onto the absorbent article when worn. At the same time, the absorbent article should be thin so that the absorbent article may be worn in an inconspicuous manner. From the manufacturer's point of view, the materials used to produce the absorbent article must be suitable for mass production at very high production rates. The materials used to produce the absorbent article must therefore be easily obtained and be of relatively low cost. Furthermore, the materials must be easily processed at high speeds, which often include considerable forces and tensions being applied to the material, especially in the machine direction. [0003] In order to increase the wearing comfort of sanitary napkins it has been suggested in the art to provide these articles with stretchability or increased flexibility. One method suggested in the art is to provide slits in the materials used to form the absorbent article. Excessive extensibility of an absorbent layer in the longitudinal direction, which is generally the machine direction, will make it very difficult to prepare such an absorbent layer on a production line designed for very high production rates (high speeds). Furthermore, for the absorbent article to be able to conform to the body of the wearer, the absorbent layer should be sufficiently extensible in both the longitudinal and lateral direction, while maintaining sufficient strength in both directions. At the same time, care must be taken not to significantly reduce the flexural resistance of the absorbent article. If the flexural resistance is reduced too much, the absorbent article will bunch, twist or rope or form lumps when the article is worn. Additionally, the articles might not be accepted by the consumer if the absorbent article feels too flexible, i.e. flimsy or flabby, thereby creating the impression that the article will not provide sufficient protection against the soiling of the garment to be protected. Furthermore, care should be taken that the formation of slits in the absorbent layer does not impair the efficiency of liquid intake, liquid distribution and liquid retention, due to the quick passage of liquid through the absorbent layer via the cuts or apertures formed therein. [0004] A current trend in feminine hygiene products is to provide these products with aesthetic features such as colors, apertures and embossing to provide the consumer with a sense that the feminine hygiene products will be effective in absorbing bodily fluids. Color can be used to show the consumer or user that the product has new features, absorbency, and leakage protection. [0005] There is a need in the art to provide an absorbent article which is extensible and highly conformable to the body of the wearer, while at the same time maintaining sufficient structural strength to avoid bunching, twisting or roping and the formation of lumps. In addition, there is a need in the art to make efficient usage of the absorbent capacity of the absorbent layer, and having the ability to produce the absorbent layer at high production rates (high speeds) at relatively reasonable or low cost. In addition, there is a need to provide additional color or features to absorbent products and to provide a way to convey these additional features to the consumer or user of these products. SUMMARY OF THE INVENTION [0006] The present invention provides an absorbent article which is extensible and highly conformable to the body of the wearer. Furthermore, the present invention provides an extensible and highly conformable absorbent layer for an absorbent article which efficiently utilizes the absorbent capacity of the absorbent layer. The present invention solves the above outlined problems by providing an absorbent article, an absorbent layer for use in an absorbent article, and a process for manufacturing the absorbent layer. Further embodiments and features of the different aspects of the present invention become apparent in the detailed description and the figures appended thereto. [0007] The absorbent article of the present invention has a longitudinal direction and a lateral direction. In addition, the absorbent article has a top layer, a backing layer, and an absorbent layer positioned between the top layer and the backing layer. The absorbent layer is prepared from an absorbent nonwoven web having a first plurality of slits with a first orientation and a second plurality of slits with a second orientation, wherein the first orientation is different from the second orientation. The first plurality of slits and the second plurality of slits are at least partially through the absorbent nonwoven web, and the second plurality of slits at least partially intersects the first plurality of slits in a manner such that where the first and second plurality of slits intersect the first and second plurality of slits combine to form apertures in the absorbent nonwoven web. The first plurality of slits may be non-linear and the second plurality of slits may also be non-linear. [0008] In further embodiments of the present invention, the top layer of the absorbent article may be a liquid-permeable material and the bottom layer may be a liquid-impermeable material. In addition, the basis weight of the absorbent nonwoven web may be between about 20 g/m.sup.2 and 1000 g/m.sup.2. Further, the basis weight of the absorbent nonwoven web may be between about 50 g/m.sup.2 and 500 g/m.sup.2 and generally between about 70 g/m.sup.2 and 250 g/m.sup.2. [0009] In yet a further embodiment of the present invention, the first plurality of slits may be non-linear. Likewise, the second plurality of slits may also be non-linear. Each non-linear slit has an effective length in longitudinal direction in the range between about 2 mm and about 20 mm and an effective length in lateral direction in the range between about 0.5 mm and about 10 mm. [0010] In another embodiment of the present invention, provided is an absorbent nonwoven web having a first plurality of slits with a first orientation and a second plurality of slits with a second orientation, wherein the first orientation is different from the second orientation. The first plurality of slits and the second plurality of slits are at least partially through the absorbent nonwoven web, and the second plurality of slits at least partially intersects the first plurality of slits in a manner such that where the first and second plurality of slits intersect the first and second plurality of slits combine to form apertures in the absorbent nonwoven web. [0011] In another embodiment of the present invention, provided is a process for preparing a web, in particular the absorbent nonwoven web of the absorbent layer of the present invention. In this embodiment, the process has the steps of a) providing a web; b) providing a slitting apparatus having anvil roll, a first cutting roll and a second cutting roll; c) passing the web between the first cutting roll and the anvil to form a first plurality of slits in the absorbent nonwoven web; and d) passing the web between the second cutting roll and the anvil to form a second plurality of slits in the absorbent nonwoven web, wherein at least one slit in the second plurality of slits intersects at least one slit from the first plurality of slits such that an aperture is formed in the web. In the process of the present invention, both the first and second cutting rolls are positioned adjacent the same anvil roll. That is, the first cutting roll and the second cutting roll place slits in the absorbent nonwoven web against the same anvil roll. The absorbent nonwoven web of the present invention is brought into contact with the anvil roll, cut with the first cutting roll. Once cut or slitted with the first cutting roll, the web remains in contact with the anvil roll and is cut or slit with the second cutting roll. The first and second cutting rolls may be run in unison to register the first and second slits cut into the web. [0012] In another embodiment of the present invention, provided is an apparatus for aperturing a web. The apparatus has an anvil roll, a first cutting roll and a second cutting roll, wherein the first cutting and second cutting rolls are in communication with the anvil roll. Each cutting roll has a series of protrusions that are capable of forming slits in a web passed between the anvil and each cutting roll. At least some of the protrusions of the first cutting roll and some of the protrusions of the second cutting roll are aligned on the anvil such that at least a portion of slits cut by the first cutting roll overlap at least a portion of the slits cut by the second cutting roll in the area where the slits overlap one another. In a further embodiment of the apparatus of the present invention, there may be at least one additional cutting roll in communication with the anvil. Each additional cutting roll has a series of protrusions that are capable of forming slits in a web passed between the anvil and each cutting roll. Each cutting roll may be run in unison with the anvil roll. BRIEF DESCRIPTION OF THE DRAWINGS [0013] FIG. 1 is an exploded view of a first embodiment of an absorbent article according to the present invention. [0014] FIG. 2 is an exploded view of a second embodiment of an absorbent article according to the present invention. [0015] FIGS. 3A-F show possible arrangements for a plurality of slits in a pattern or orientation. [0016] FIG. 4 shows an absorbent layer of the present invention with slits in a first orientation and slits in a second orientation that combine to form apertures. [0017] FIG. 5 shows an absorbent layer of the present invention with slits in a first orientation and slits in a second orientation that combine to form apertures. [0018] FIGS. 6A and 6B show a configuration of three slits which combine to form an aperture. [0019] FIG. 7 shows a schematic representation of a section of a pattern of slits usable in the absorbent layer. [0020] FIG. 8A shows a schematic representation of an apparatus of the present invention with two slitting rolls Continue reading about Extensible absorbent layer and absorbent article... Full patent description for Extensible absorbent layer and absorbent article Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Extensible absorbent layer and absorbent article patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. 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