Laminate webs and absorbent articles having the same
Inventors
Cecchetto, Pietro • Sauer, Linda Ann • Li, Shihuang
Assignees
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Publication Number
US-12575980-B2
Publication Date
2026-03-17
Expiration Date
Abstract
A laminate web having a polymer film layer and a nonwoven layer is disclosed. The polymer film layer makes up a first side of the laminate web and the nonwoven layer makes up a second side of the laminate web. The laminate web has a plurality of first elements extending from the polymer film. The web also has a plurality of second elements such as recesses, protrusions, apertures, embossing and combinations thereof.
Core Innovation
The invention relates to an absorbent article comprising a liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent core, with the topsheet including a laminate web. The laminate web includes a first layer comprising a polymer film and a second layer comprising a carded nonwoven web, where the polymer film and nonwoven web are joined to form a precursor laminate having a first side defined by the polymer film and an opposing second side defined by the nonwoven.
The first layer has a pattern of relatively smaller apertures formed therethrough, with at least about 95 discrete apertures per square centimeter and apertures having a diameter of less than about 500 microns. The laminate also has a pattern of relatively larger protrusions or relatively larger recesses formed therein, and a plurality of the relatively smaller apertures are present within each of a plurality of the protrusions or recesses.
Each larger protrusion or recess defines a void area interiorly and includes a base coplanar with the first side, a plateau, and a sidewall extending from the plateau to the base, with the base wider than the plateau. The first layer is stretched to form the larger protrusions or recesses such that the portion forming each larger feature has a reduced thickness as compared to the base, and the patterns extend throughout the liquid permeable topsheet while the first layer is the outermost layer facing the skin of the wearer.
Claims Coverage
The partial content provides two independent claims. Across these claims, the inventive coverage centers on a laminate topsheet structure that combines a polymer film with a carded nonwoven, and includes a specific pattern relationship between relatively smaller apertures and relatively larger protrusions or recesses formed by stretching a polymer film outermost layer.
Laminate topsheet with patterned apertures and protrusions or recesses
A liquid permeable topsheet comprising a laminate web including a first layer comprising a polymer film and a second layer comprising a nonwoven web, where the polymer film and nonwoven web are joined to form a precursor laminate having a first side defined by the polymer film and an opposing second side defined by the nonwoven; the first layer has a pattern of relatively smaller apertures formed therethrough; the laminate has a pattern of relatively larger protrusions or relatively larger recesses formed therein such that the relatively larger protrusions or recesses are of a size sufficient for a plurality of the relatively smaller apertures to be present within each of a plurality of the protrusions or recesses.
Void area geometry with coplanar base and plateau sidewall
Each larger protrusion or recess defines a void area interiorly and includes a base coplanar with the first side; each larger protrusion or recess comprises a plateau and a sidewall extending from the plateau to the base, wherein the base is wider than the plateau.
Stretching the polymer film to reduce thickness at larger features
The first layer is stretched to form the larger protrusions or recesses such that a portion of the first layer forming each larger protrusion or recess has a reduced thickness as compared to the base.
Outermost skin-facing film layer with extending aperture and protrusion or recess patterns
The first layer is an outermost layer of the absorbent article facing the skin of the wearer, wherein the pattern of relatively smaller apertures and the pattern of relatively larger protrusions or relatively larger recesses extends throughout the liquid permeable topsheet.
Specific aperture density and carded nonwoven
The first layer includes at least about 95 discrete apertures per square centimeter having a diameter of less than about 500 microns, and the nonwoven web comprises a carded nonwoven.
Across independent claims, the laminate topsheet is defined by a polymer film joined to a carded nonwoven, with a skin-facing outermost polymer film layer carrying a first pattern of relatively smaller apertures and a second pattern of relatively larger protrusions or recesses. The larger features include a void area with a coplanar base and plateau/sidewall geometry, and the polymer film is stretched so that the film portion forming each larger feature has reduced thickness compared with the base.
Stated Advantages
Not explicitly described in patent.
Documented Applications
Absorbent articles including sanitary napkins and diapers are described as using the described laminate topsheet structure.
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