Sanitary napkin having an independently displaceable central core segment

A sanitary napkin is disclosed having an absorbent core comprising a central core segment and two side core segments. The sanitary napkin also includes a lifting member for displacing the central core segment relative to the side core segments.

FIELD OF THE INVENTION 
The present invention relates generally to disposable absorbent articles 
such as sanitary napkins and, more particularly, to a sanitary napkin 
having an absorbent core comprising distinct core segments, and a lifting 
member for providing independent displacement of at least one of the core 
segments relative to the other core segments 
BACKGROUND OF THE INVENTION 
Absorbent articles such as sanitary napkins, pantiliners, and incontinence 
pads are designed to absorb and retain liquid and other discharges from 
the human body, and to prevent soiling of the body and clothing by such 
discharges. It is generally desirable to provide absorbent articles such 
as sanitary napkins which maintain contact with the body of the wearer 
when they are worn, and which conform as closely as possible to the body 
of the wearer. Such body conforming capability is believed to increase the 
effectiveness of the sanitary napkin by reducing the possibility that 
menses will travel around the perimeter of the sanitary napkin and soil 
the wearer's body and/or clothing. 
There have been a number of recent efforts to provide sanitary napkins and 
other absorbent articles with improved fit characteristics. Such recent 
efforts are described in U.S. Pat. No. 4,950,264 issued Aug. 21, 1990 to 
Osborn, U.S. Pat. No. 5,007,906 issued Apr. 16, 1991 to Osborn; U.S. Pat. 
No. 5,197,959 issued Mar. 30, 1993 to Buell; U.S. patent application Ser. 
No. 07/605,583 entitled "Sanitary Napkin Having Components Capable of 
Separation In Use" filed Oct. 29, 1990 in the name of Visscher et al.; and 
PCT International Publication Number WO 92/07535 published May 14, 1992 in 
the name of Visscher et al. In addition, the following commonly assigned 
and copending U.S. Patent Applications provide sanitary napkins having 
internal shaping components and lifting members: "Sanitary Napkin Having a 
Pleated Lifting Member," Ser. No. 08/170,461 filed Dec. 20, 1993 in the 
name of McFall; and "Sanitary Napkin Having an Internal Shaping 
Component," Ser. No. 08/170,487 filed Dec. 20, 1993 in the name of 
Bergman. 
There have also been efforts to provide a disposable absorbent articles 
having two or more absorbent portions or layers. The following documents 
describe disposable absorbent articles having multiple absorbent portions 
or layers: Great Britain Patent 23,103 issued Oct. 28, 1915 to Mycroft; 
U.S. Pat. No. 3,071,138 issued Jan. 1, 1963 to Garcia; U.S. Pat. No. 
3,653,382 issued Apr. 4, 1972 to Easley et al.; U.S. Pat. No. 3,954,107 
issued May 4, 1976 to Chesky et al.; U.S. Pat. No. 4,340,058 issued Jul. 
20, 1982 to Pierce; U.S. Pat. No. 4,589,876 issued May 20, 1986 to Van 
Tilburg; U.S. Pat. No. 4,973,325 issued Nov. 27, 1990 to Sherrod et al; 
U.S. Pat. No. 4,988,344 issued Jan. 29, 1991 to Reising et al.; and U.S. 
patent application Ser. No. 07/827,555 entitled "Sanitary Napkin Having 
Transversely Segmented Core," filed in the name of Osborn, III on Jan. 28, 
1992 (continuation of Ser. No. 07/630,451 filed Dec. 19, 1990). 
While the sanitary napkins disclosed in these references represent 
advancements in the art, the search for new and different ways of 
improving body contact has continued. 
It is especially desirable that the sanitary napkin maintain contact with 
and conform to the body of the wearer under dynamic conditions (when the 
wearer walks, sits, etc.). For instance, when the sanitary napkin is worn, 
the sanitary napkin is subjected to lateral compression by the upper 
portions of the wearer's thighs. The forces applied by the wearer's thighs 
generally tend to distort the shape of the sanitary napkin, reducing the 
size of the target the sanitary napkin provides. 
One attempt to control the effect of these compressive forces is disclosed 
in UK Patent Application 2,168,612A, published Jun. 25, 1986. The UK 
patent application discloses a sanitary towel with a resilient insert 
positioned within the core or adjacent to a face of the core that is 
intended to inhibit permanent distortion of the towel. The UK application 
teaches that the insert resists lateral deformation of the sanitary towel, 
but does not teach or disclose a sanitary napkin having body conforming 
properties. 
It is also desirable to provide a sanitary napkin which conforms to the 
wearer's body while maintaining the comfort of the wearer. Accordingly, a 
desirable sanitary napkin should maintain contact with the wearer's body, 
yet be capable of repeated elastic deflection to allow the wearer to 
comfortably assume different positions and to perform different 
activities. 
It is therefore an object of this invention to provide an absorbent 
article, such as a sanitary napkin, which intercepts menses by conforming 
to the shape of the female urogenital region. 
It is another object of the present invention to provide an absorbent 
article having a bi-level core and a bi-level body facing surface. 
Another object of the present invention to provide a sanitary napkin having 
separate core segments. 
Yet another object of the present invention is to provide a sanitary napkin 
having a lifting member for displacing a central absorbent core segment 
relative to side absorbent core segments. 
These and other objects of the present invention will be more readily 
apparent when considered in reference to the following description and 
when taken in conjunction with the accompanying drawings. 
SUMMARY OF THE INVENTION 
The present invention is an absorbent article, such as a sanitary napkin 
having a longitudinal centerline, a lateral centerline, and first and 
second longitudinally extending sides joining first and second laterally 
extending ends. The sanitary napkin of the present invention has a liquid 
pervious topsheet having a body facing surface, a liquid impervious 
backsheet joined to the topsheet, an absorbent core disposed intermediate 
the topsheet and the backsheet, and a lifting member disposed intermediate 
a portion of the absorbent core and the backsheet. 
The absorbent core comprises a central core segment having a lateral width 
less than the total lateral width of the absorbent material in the 
sanitary napkin. The central core segment extends along the longitudinal 
centerline of the sanitary napkin. The absorbent core also includes a 
first longitudinally extending side core segment disposed intermediate the 
longitudinal centerline and the first longitudinally extending side of the 
sanitary napkin, and a second longitudinally extending side core segment 
disposed intermediate the longitudinal centerline and the second 
longitudinally extending side of the sanitary napkin. The first and second 
side core segments are preferably separate from the central core segment. 
The lifting member is disposed intermediate the backsheet and the central 
core segment for providing Z-direction displacement of the central core 
segment relative to the first and second side core segments. The lifting 
member is preferably a longitudinally extending lifting member having a 
plurality of pleats along its length. The lifting member can comprise a 
pleated first element and a second element joined to the first element at 
spaced apart locations along the length of the first element, wherein 
elastic contraction of the second element relative to the first element 
gathers the first element to form pleats in the first element. 
In one embodiment the sanitary napkin further comprises a wicking member, 
which is preferably a tissue paper web comprising cellulosic fibers. The 
wicking member conveys fluid intermediate the central core segment and the 
first and second side core segments. The wicking member can have a central 
portion disposed intermediate the central core segment and the lifting 
member, a first side portion disposed intermediate the backsheet and the 
first side core segment, and a second side portion disposed intermediate 
the backsheet and the second side core segment.

DETAILED DESCRIPTION OF THE INVENTION 
FIGS. 1-4 illustrate a sanitary napkin 20 according to one embodiment of 
the disposable absorbent article of the present invention. As used herein, 
the term "absorbent article" refers to articles which absorb and contain 
body exudates. More specifically, the term is intended to include, but not 
be limited to, sanitary napkins, pantiliners, and incontinence pads 
(articles worn in the crotch region of a garment). The term "disposable" 
refers to articles which are intended to be discarded after a single use 
rather than laundered or otherwise restored or reused. 
The sanitary napkin 20 has a perimeter having first and second 
longitudinally extending sides 28A and 28B joining first and second 
laterally extending ends 30A and 30B. The sanitary napkin also has a 
longitudinal centerline 29 and a lateral centerline 31. As used herein the 
term "longitudinal" refers to a line, axis, or direction generally aligned 
with the vertical plane which bisects the standing wearer into left and 
right body halves. The term "lateral" refers to a line, axis, or direction 
generally perpendicular to the longitudinal direction and lying within the 
plane of the sanitary napkin 20. The sanitary napkin 20 is typically 
longer in the longitudinal direction than in the lateral direction. 
The "Z" direction refers to a line, axis, or direction which is 
perpendicular to the plane of the sanitary napkin (i.e., perpendicular to 
both the longitudinal axis 29 and the lateral axis 31 when the sanitary 
napkin is supported in a generally flat configuration). The Z direction is 
illustrated in FIG. 3. 
The sanitary napkin 20 according to the present invention comprises a 
liquid pervious topsheet 40 having a body facing surface 42; a liquid 
impervious backsheet 50 having a garment facing surface 52; and an 
absorbent core 60 disposed intermediate the topsheet 40 and the backsheet 
50. 
The absorbent core 60 comprises a three piece construction which includes a 
central core segment 62 extending along the longitudinal centerline 29, a 
first longitudinally extending side core segment 64, and a second 
longitudinally extending side core segment 66. The first and second core 
side segments 64 and 66 are disposed intermediate the longitudinal 
centerline 29 and the first and second longitudinally extending sides 28A 
and 28B of the sanitary napkin 20, respectively. The absorbent core 60 has 
a longitudinal length L (FIG. 4) measured along the longitudinal 
centerline 29 which is typically greater than the absorbent core's lateral 
width W (FIG. 2) measured along the lateral centerline 31. 
The sanitary napkin 20 according to the present invention further comprises 
a lifting member 100 disposed intermediate the backsheet 50 and the 
central core segment 62. The lifting member 100 can be disposed laterally 
intermediate the first and second core side segments 64 and 66. The 
lifting member 100 provides Z-direction elastic displacement of the 
central core segment 62 relative to the first and second side core 
segments 64 and 66 and the backsheet 50. 
By "Z-direction elastic displacement" of the central core segment 62 
relative to the backsheet 50 and the side core segments 64,66, it is meant 
that the central core segment 62 can be displaced relative to the 
backsheet 50 and the side core segments 64,66 in the Z-direction from a 
first, extended configuration, wherein the sanitary napkin 20 has a 
Z-direction caliper Z1 shown in FIGS. 3 and 4, to a second compressed 
configuration having a caliper Z2 shown in FIG. 2 (such as by the 
compressive Z-direction load 200), and that the lifting member 100 will 
restore the sanitary napkin 20 to have a Z-direction caliper which is at 
least about 70 percent of the Z-direction caliper Z1 upon release of the 
compressive loading, when the sanitary napkin is dry and has not been 
loaded with body exudates. The elastic displacement of the topsheet 22 
relative to the backsheet 24 can be expressed by the difference Z1-Z2. 
The Z-direction calipers Z1 and Z2, and the corresponding Z-direction 
compressive loading are measured using a suitable tensile testing machine, 
such as an Instron Model 4502 tensile testing machine manufactured by the 
Instron Engineering Corporation of Canton, Mass. The Z-direction calipers 
Z1 and Z2 are measured using the procedure described in U.S. patent 
application Ser. No. 08/170,461, Sanitary Napkin Having a Pleated Lifting 
Member, filed Dec. 20, 1993 in the name of McFall, which application is 
incorporated herein by reference. 
By lifting the central core segment 62 relative to the side core segments 
64, 66, the lifting member 100 maintains contact of a portion of the 
topsheet 40 overlying the central core segment 62 and extending along the 
longitudinal centerline 29 with the wearer's body. The lifting member 100 
convexly shapes the body facing surface 42 of the topsheet 40 to conform 
to the wearer's body, particularly in the labia, perineum, and/or gluteal 
groove areas. The lifting member 100 also biases the central core segment 
62 into engagement with the portion of the topsheet 40 along the 
longitudinal centerline 29 to enhance acquisition of body fluids by the 
central core segment 62 from the portion of the topsheet 40 extending 
along the longitudinal centerline 29. 
The central core segment 62 preferably has a lateral width W1 (FIG. 3) 
measured along the lateral centerline 31 which is less than the lateral 
width W of the absorbent core 60. A lateral width W1 which is less than 
the lateral width W reduces the weight of absorbent material displaced by 
the lifting member 100. Reducing the weight of absorbent material 
displaced by the lifting member 100 reduces the required stiffness of the 
lifting member 100, and thereby provides a more comfortable fit for the 
wearer. The side core segments 64 and 66 preferably have lateral widths W2 
and W3 which are less than the width W of the absorbent core 60. The side 
core segments 64 and 66 can be laterally spaced apart a distance greater 
than the width W1 so that the center core segment 62 is positioned 
laterally intermediate the side core segments 64 and 66 when the sanitary 
napkin 20 is compressed as shown in FIG. 2. 
The lifting member 100 displaces the central core segment 62 to extend 
above the plane of the side core segments 64 and 66. The lifting member 
100 thereby provides a bi-level core 60 and a bi-level body facing surface 
42 of the topsheet. Such a bi-level core 60 and bi-level body facing 
surface 42 improves body fit by providing enhanced contact with the labia, 
perineum, and gluteal groove areas of the body. In addition, a lateral 
width W1 which is less than the lateral width W promotes convex shaping of 
the body facing surface 42 of the topsheet 40 along the longitudinal 
centerline 29, and thereby enhances fit in the labia, perineum, and/or 
gluteal groove areas of the body. 
The central core segment 62 is preferably separate from the first and 
second core side segments 64 and 66. The central core segment should be 
separate from the first and second core segments 64 and 66 so that the 
lifting member 100 can displace the central core segment 62 independently 
of the side core segments 64 and 66. By the term "separate" it is meant 
that the central core segment 62 is not an extension of, nor directly 
joined or directly connected to either of the first and second core side 
segments 64 and 66 by adhesive or other fastening means. Of course, the 
central core segment 62 can be separate from the first and second side 
core segments 64 and 66 and yet be indirectly joined to the side core 
segments 64 and 66 by one or more other elements of the sanitary napkin 
20. For instance, the topsheet 40 can be directly joined to each of the 
core segments 62, 64, and 66, and thereby indirectly join the core 
segments 62, 64 and 66. 
Referring to FIGS. 2 and 3, the sanitary napkin 20 according to the present 
invention can have a wicking member 70 for conveying body fluids from the 
central core segment 62 to the first and second side core segments 64 and 
66. The wicking member 70 can also provide lateral support for the lifting 
member 100 when the sanitary napkin is in the extended position shown in 
FIGS. 3 and 4. The wicking member 70 can comprise a web of cellulosic 
fibers, such as a web of tissue paper. The wicking member 70 can have a 
first longitudinally extending side portion 74, a second longitudinally 
extending side portion 76, and a longitudinally extending central portion 
72 extending laterally intermediate the first and second side portions 74 
and 76. The first side portion 74 is disposed intermediate the first side 
core segment portion 64 and the backsheet 50. The second side portion 76 
is disposed intermediate the second side core segment 66 and the backsheet 
50. The central portion 72 is disposed intermediate the central core 
segment 62 and the lifting member 100. The wicking member 70 can have a 
pair of longitudinally extending folds 71 for accommodating extension of 
the lifting member 100 in the Z-direction. 
The sanitary napkin 20 according to the present invention can also have a 
support member 80. The support member 80 has a lateral width greater than 
the lateral width of the lifting member 100 and distributes loads from the 
lifting member 100 to the backsheet 50. The support member 80 also 
stiffens the structure of the sanitary napkin 20 underlying the lifting 
member 100. The support member 80 thereby helps to ensure that the lifting 
member 100 displaces the central core segment 62 upward relative to the 
side core segments 64 and 66 and the backsheet 50. 
The support member 80 can extend laterally intermediate the first and 
second side core segments 64 and 66, and can comprise a web of cellulosic 
fibers, such as a web of tissue paper. The support member 80 can have a 
first longitudinally extending side portion 84, a second longitudinally 
extending side portion 86, and a longitudinally extending central portion 
82 extending laterally intermediate the first and second side portions 84 
and 86. The central portion 82 is joined to the lifting member 100 and at 
least the first and second side portions are joined to the backsheet 50. 
The first side portion 84 is disposed intermediate the first side core 
segment 64 and the backsheet 50. The second side portion 86 is disposed 
intermediate the second side core segment 66 and the backsheet 50. The 
central portion 82 is disposed intermediate the lifting member 100 and the 
backsheet 50. The wicking member 70 and the support member 80 preferably 
have a lateral width less than the width W of the absorbent core 60 to 
prevent wicking of body exudates to the longitudinally extending sides 28A 
and 28B of the sanitary napkin 20. In the embodiment shown in FIGS. 1 
through 4 the central portion 72 of the wicking member 70 is joined to the 
lifting member 100, and the side portions 74 and 76 of the wicking member 
are joined to the side portions 84 and 86, respectively, of the support 
member 80. 
Examining the components of the sanitary napkin 20 in more detail, the 
topsheet 40 is the component of the sanitary napkin 20 oriented towards 
and contacting the body of the wearer for receiving body exudates. The 
topsheet 40 is flexible, soft feeling, nonirritating to the wearer's skin, 
and is liquid pervious. As used herein, the term flexible refers to 
materials which are compliant and readily conform to the shape of the body 
or respond by easily deforming in the presence of external forces. 
Preferably, the topsheet 40 is not noisy to provide discretion to the 
wearer. 
The topsheet 40 should be clean in appearance and can be somewhat opaque to 
hide the discharges collected in the core 60. The topsheet 40 preferably 
has a pair of laterally spaced apart and longitudinally extending folds 
41. The folds 41 in the topsheet 40 accommodate the Z-direction 
displacement of the central core segment 62. The folds 41 also permit 
independent Z-direction displacement of the central core segment 62 
relative to the core segments 64 and 66 when all three core segments are 
joined to the topsheet 40. 
The topsheet 40 is preferably joined to the backsheet along the 
longitudinal sides 28A and 28B and along one or both of the lateral ends 
30A and 30B. The topsheet 40 can be joined to the backsheet 50 to provide 
Z-direction decoupling of the topsheet 40 from the backsheet 50, as 
described in U.S. Pat. No. 5,007,906 issued Apr. 16, 1991 to Osborn et al, 
which patent is incorporated herein by reference. The topsheet 40 can be 
joined to the backsheet 50 by any suitable method, including but not 
limited to adhesive bonding, ultrasonic bonding, or thermal bonding. 
The topsheet 40 should exhibit good strike-through and rewet 
characteristics, permitting bodily discharges to rapidly penetrate the 
topsheet 40 to the core 60. A suitable topsheet 40 may be made from a wide 
range of materials, such as woven and nonwoven materials; polymeric 
materials such as apertured formed thermoplastic films, apertured plastic 
films, and hydroformed thermoplastic films; porous foams; reticulated 
foams; reticulated thermoplastic films; and thermoplastic scrims. Suitable 
woven and nonwoven materials can be comprised of natural fibers (e.g., 
wood or cotton fibers), synthetic fibers (e.g., polymeric fibers such as 
polyester, polypropylene, or polyethylene fibers) or combinations of 
natural and synthetic fibers. 
The topsheet 40 has a plurality of apertures to permit liquids deposited 
thereon to pass through to the core 60. The topsheet 40 can comprise an 
apertured formed polyolefinic film having about 5 to about 60 percent open 
area and a thickness of about 0.01 to about 0.05 millimeters. Referring to 
FIG. 5, the topsheet 40 can comprise a primary topsheet layer 44 joined to 
a secondary topsheet layer 46. The primary topsheet layer 44 can comprise 
an apertured formed polyolefinic film made in accordance with one of the 
following U.S. Patents: U.S. Pat. No. 3,929,135 issued Dec. 30, 1975 to 
Thompson; U.S. Pat. No. 4,324,246 issued Apr. 13, 1982 to Mullane; U.S. 
Pat. No. 4,342,314 issued Aug. 3, 1982 to Radel et al.; U.S. Pat. No. 
4,463,045 issued Jul. 31, 1984 to Ahr et al.; and U.S. Pat. 5,006,394 
issued Apr. 9, 1991 to Baird, which patents are incorporated herein by 
reference for the purpose of disclosing particularly preferred executions 
of liquid pervious topsheets. 
The secondary topsheet layer 46 can comprise a nonwoven web of natural or 
synthetic fibers. Suitable nonwovens from which the secondary topsheet 
layer 46 can be formed include a nonwoven web of spunbond polypropylene 
fibers designated P-9 having a basis weight of about 18 grams per square 
yard and available from the Fiberweb Corporation of Simpsonville, S.C. 
under the tradename CELESTRA. Another suitable nonwoven from which the 
secondary topsheet layer 46 can be formed is an airthrough bonded fabric 
having a basis weight of about 21 grams per square meter formed of 
bicomponent fibers, the fibers having a polyethylene sheath and a 
polypropylene or polyester core. Such an airthrough bonded fabric is 
available from the Havix Company (formerly Fukumura) of Ijra-Mura Japan as 
S2416 airthrough bonded fabric. 
The primary and secondary topsheet layers 44 and 46 are preferably joined 
together by a plurality of discrete bonds 45 (FIG. 5). The bonds 45 are 
preferably formed using the mechanical bonding method disclosed in U.S. 
Pat. No. 4,919,738 issued Apr. 24, 1990 to Ball et al., which patent is 
incorporate herein by reference. Alternatively, the layers 44 and 46 can 
be joined using other methods, including but not limited to adhesive 
bonding, ultrasonic bonding, and thermal bonding. 
The backsheet 50 may be any flexible liquid impervious material, such as a 
polyolefinic film. The backsheet 50 prevents discharges collected by the 
sanitary napkin 20 from soiling the wearer or the wearer's clothing. The 
backsheet 50 can be a low density polyethylene film about 0.01 to about 
0.05 millimeters in thickness, and preferably about 0.025 millimeters (1.0 
mil). Suitable polyethylene films from which the backsheet 24 can be 
formed are sold by the Ethyl Corp., Visqueen Division, as Model XP-39385 
and by the Clopay Corp. of Cincinnati, Ohio as SOFLEXX 1401. 
The backsheet 50 can have a surface area greater than or equal to that of 
the topsheet 40 and the absorbent core 60, and preferably peripherally 
circumscribes the topsheet 40 and the core 60. The backsheet 40 may 
comprise flaps (not shown) extending outwardly from each longitudinally 
side 28A and 28B. The flaps may be made in accordance with the teachings 
of U.S. Pat. Nos. 4,589,876 issued May 20, 1986 to Van Tilburg and U.S. 
Pat. No. 4,687,478 issued Aug. 18, 1987 to Van Tilburg, which patents are 
incorporated by reference. The backsheet 50 and the flaps may be unitary 
and coextensive. Alternatively, the flaps can be separate components 
joined to the backsheet. 
The garment facing surface 52 of the backsheet 50 may comprise an 
attachment means 56 (FIG. 5) for securing the sanitary napkin 20 to the 
undergarment of the wearer. Preferred attachment means 56 include 
mechanical fasteners, or more preferably, pressure sensitive adhesive. The 
pressure sensitive adhesive may be applied to the garment facing surface 
52 in one or more strips or patches. A suitable adhesive is Century 
Adhesive A-305-IV manufactured by Century Adhesives Corp. of Columbus 
Ohio. A strip of silicone coated release paper 57 can cover the adhesive 
to prevent soiling of the adhesive prior to use. In one embodiment two 
parallel strips of pressure adhesive can be applied to the garment facing 
surface 52, each strip of adhesive underlying one of the side core 
segments 64, 66. 
The absorbent core 60 receives and contains body exudates, particularly 
menses. Suitable materials from which the core segments 62, 64 and 66 
include a wide variety of liquid-absorbent materials such as comminuted 
cellulosic wood pulp fibers, which is generally referred to as airfelt. 
Examples of other suitable materials include but are not limited to creped 
cellulose wadding; meltblown polymers, chemically stiffened, modified, or 
cross-linked cellulosic fibers; absorbent foams; layers of tissue paper; 
and absorbent gelling materials. 
In the embodiment shown in FIGS. 1-7 each of the absorbent core segments 
62, 64, and 66 comprises an airlaid airfelt pad of cellulose fibers, which 
fibers are available from the Foley, Fla. plant of the Buckeye Cellulose 
Company of Memphis, Tenn. The core segments 62, 64 and 66 can be formed 
exclusively of cellulose fibers, or alternatively, can include other 
materials such as absorbent gelling materials in addition to cellulose 
fibers. 
Each of the core segments 62, 64, and 66 can have a length of about 200 
millimeters. The widths W1, W2, and W3 (FIG. 3) can each be about 25 
millimeters. Each of the core segments 62, 64, and 66 can have a thickness 
t (FIG. 4) of about 4.9 millimeters in the absence of confining pressure. 
The combined weight of the core segments 62, 64, and 66 can be about 4.1 
grams, with each core segment weighing about 1.37 grams. 
The core segments can be airlaid separately, or formed as a unitary pad, 
and then separated into individual core segments. The following U.S. 
Patents are incorporated herein by reference for the purpose of disclosing 
suitable methods for forming airlaid webs of fibers: U.S. Pat. 4,388,056 
issued Jun. 14, 1983 to Lee et al.; U.S. Pat. No. 4,551,191 issued 
November 1985 to Kock et al.; U.S. Pat. No. 4,592,708 issued Jun. 3, 1986 
to Feist et al.; and U.S. Pat. Nos. 4,765,780 and 4,908,175 issued Aug. 
23, 1988 and Mar. 13, 1990 respectively to Angstadt et al. 
Absorbent cores can be formed in discrete cavities on a laydown drum, as 
disclosed in U.S. Pat. No. 4,859,388 issued Aug. 22, 1989 to Peterson et 
al., which patent is incorporated herein by reference. FIG. 12 shows an 
airfelt deposition mold 500 suitable for forming the core segments 62, 64, 
and 66 on an airfelt laydown drum. A plurality of the molds 500 are 
mounted on the circumference of the laydown drum, which rotates in a 
machine direction (MD) indicated in FIG. 12. Each mold 500 has a top 
arcuate surface 502. Together, the arcuate top surfaces 502 of the molds 
500 form the perimeter of the laydown drum. The machine direction 
corresponds to the longitudinal direction on the sanitary napkin 20. The 
cross machine direction (CD) is generally parallel to the axis of rotation 
of the laydown drum, and corresponds to the lateral direction on the 
sanitary napkin 20. The mold 500 comprises a deposition cavity 510 formed 
in the arcuate top surface 502. The deposition cavity 510 is bounded by a 
perimeter sidewall 520 and a foraminous bottom wall 530. The foraminous 
bottom wall 530 can comprise a screen. Airflow through the foraminous 
bottom wall 530 is created by a vacuum within the laydown drum. The 
airflow through the foraminous bottom wall 530 carries cellulosic fibers 
into the cavity 510 for deposition on the foraminous bottom wall 530. 
According to the present invention, the cores segments 62, 64, and 66 can 
be formed to be interconnected in a mold 500 having two generally parallel 
partitions 550. Referring to FIG. 13, each partition 550 has an arcuate 
top edge 552 concentric with an arcuate bottom edge 554, and a pair of 
beveled side edges 556. The edges 552, 554, and 556 extend between 
oppositely facing sidewalls 558. The beveled side edges 556 engage grooves 
522 in the perimeter sidewall 520 of the deposition cavity 510. The 
foraminous bottom wall 530 supports the bottom edge 554 of each partition 
550, and prevents the partition 550 from falling out of the grooves 522. 
The top arcuate edge 552 of each partition 550 is flush with the top 
arcuate surface 502 of the mold 500 when the partition 550 is supported in 
the grooves 522. 
The partitions 550 extend in the machine direction and divide the 
deposition cavity 510 into three cavity segments 510A, 510B, and 510C. 
Fibers deposited in the cavity segments 510A, B, and C form the core 
segments 62, 64, and 66, respectively. Each partition 550 can have one or 
more passageways along its length for interconnecting adjacent cavity 
segments 510A/B and 510A/C. Referring to FIGS. 12 and 13, the passageways 
can comprise slots 553 in the top edge 552 which extend in the 
cross-machine direction through the thickness of the partition 550. Fibers 
deposited in the slots 553 as the cavity segments 510A-C are filled form a 
bridge between adjacent cores segments 62/64, and 62/66. The slots 553 
thereby provide structural interconnection between the core segments 62/64 
and 62/66 as fibers are deposited in the cavity segments. In alternative 
embodiments the partitions 550 can extend in the cross-machine direction, 
or in both the machine and cross-machine directions. 
For the core segments 62, 64, and 66 described above, the partitions 550 
can be formed from stainless steel sheet stock having a thickness 562 of 
about 1.6 millimeter, and have a height 564 of about 9.5 millimeter. The 
arcuate top edge 552 can be formed on a radius of about 409 millimeters 
and have a cord length 566 of about 203 millimeter. The arcuate bottom 
edge 554 can be formed on a radius of about 399 millimeters and have a 
cord length 568 of about 205 millimeters. The slots 553 can have a height 
572 of about 3.2 millimeters and a width 574 of about 6.3 millimeters. The 
slots 553 can be spaced apart on the top edge 552 by an angle 576 of about 
8 degrees. The side edges 556 can be beveled at an angle 578 of about 5 
degrees. 
The mold 500 having partitions 550 provides the advantage that the core 
segments 62, 64, 66 can be formed and conveyed as a unit, and subsequently 
separated at any desired point prior to, or after, joining the core 
segments 62, 64, 66 to other components of the sanitary napkin 20. The 
mold 500 having partitions 550 can also be used to form core segments 62, 
64, and 66 from different materials, or having different density or basis 
weight characteristics. Different core segments can be formed by directing 
different materials or different quantities of the same material into the 
cavity segments 510A-C, or by varying the vacuum within the laydown drum 
to vary the air drawn through the portion of the foraminous bottom surface 
530 subjacent each of the cavity segments 510A-C. Alternatively, the 
absorbent core 60 can be formed as a single airfelt pad, and then cut 
longitudinally to provide the individual core segments 62, 64, and 66. 
However, such cutting can result in undesirable densification of the cut 
edges of the core segments. 
Referring to FIGS. 1-4, the lifting member 100 displaces the central core 
segment 62 relative to the backsheet 50 and the side core segments 64 and 
66. In one embodiment the lifting member 100 comprises a plurality of 
pleats 115. The pleats 115 provide Z-direction elastic displacement of the 
central core segment 62 and a portion of the topsheet 40 along the 
longitudinal centerline 29 relative to the side core segments 64,66 and 
the backsheet 50. The lifting member 100 thereby provides a bi-level core 
60 and a bi-level body facing surface 42 of the topsheet. The pleats 115 
also preferably convexly shape a portion of the body facing surface 42 of 
the topsheet 40 along the longitudinal centerline 29, as shown in FIG. 3. 
The lifting member 100 thereby maintains contact of the portion of the 
topsheet 40 along the longitudinal centerline 29 with the wearer's body, 
and shapes the topsheet 40 to conform to the wearer's body, particularly 
in the labia, perineum, and/or gluteal groove areas. 
The lifting member 100 can comprise a longitudinally extending first 
pleated element 110 having a plurality of pleats 115 along its length. 
Each pleat 115 has a Z-direction height H1 (FIG. 4) when the sanitary 
napkin 20 is in the extended position shown in FIGS. 3 and 4. The lifting 
member 100 preferably also includes a longitudinally extending second 
element 120 disposed intermediate the first element 110 and the central 
core segment 62. The lifting member 100 can also include a longitudinally 
extending third element 130 disposed intermediate the first element 110 
and the backsheet 50. In the embodiment shown in FIGS. 2-4, the second 
element 120 is positioned between the first element 110 and the first 
wicking member 70, and the third element 130 is positioned between the 
first element 110 and the support member 80. 
The second and third elements 120 and 130 can be joined to the first 
element 110 at spaced apart locations along their respective lengths. The 
pleats 115 extend between the second and third elements 120, 130. The 
second and third elements 120 and 130 bridge adjacent pleats 115 and 
stabilize the pleats 115 to help prevent lateral collapse (such as by 
buckling) of the pleats 115 when the sanitary napkin is in the extended 
position shown in FIG. 3. 
The second element 120 preferably comprises an elastic element. Elastic 
contraction of the elastic second element 120 gathers the first element 
110 about fold lines generally parallel to the lateral centerline 31 to 
form the pleats 115 along the length of the first element 110. The second 
element 120 is also preferably elastic to provide a force for maintaining 
the Z-direction height of the pleats 115, and for restoring the 
Z-direction height of the pleats 115 when the pleats 115 are compressed by 
a Z-direction load such as the compressive load 200 shown in FIG. 2. The 
pleats 115 are compressed by the load 200, such as when the wearer is 
sitting, to provide for the comfort of the wearer. When the compressive 
load 200 is removed (e.g., when the wearer stands up), contraction of the 
elastic second element 120 restores the Z-direction height of the pleats 
115 and thereby maintains contact of the topsheet 40 with the wearer's 
body. 
The third element 130 can also comprise an elastic third element 130. In 
one embodiment both of the second and third elements 120 and 130 are 
elastic elements, and elastic contraction of one or both of the elastic 
second and third elements 120, 130 gathers the first elastic element 110 
to form the pleats 115. In yet another embodiment the first element 110 
can also comprise an elastic element. 
The term "elastic element" refers to a component which has a free length, 
and which can be strained by a tensile force to have a percentage of 
elongation of at least 35 percent (elongated length greater than or equal 
to 1.35.times.free length), and wherein upon release of the tensile force 
the component contracts to within 5 percent of its free length within ten 
seconds. 
In one embodiment, the ability of the lifting member 100 to restore the 
Z-direction caliper of the sanitary napkin 20 is relatively unaffected by 
wetting of the lifting member 100. The lifting member 100 can have a wet 
caliper reduction which is no more than about 20 percent greater than its 
dry caliper reduction, and a wet caliper reduction of no more than about 
eight percent. The wet caliper reduction and dry caliper reduction for the 
lifting member 100 are measured using the following procedure repeated for 
four lifting member samples. 
The lifting member 100 is adhesively attached to a sheet of polyethylene 
film having a thickness of about 1.0 mil. The lifting member 100 and 
polyethylene film are supported on the horizontal surface of an analytical 
balance, or other suitable scale. The Z-direction caliper of the lifting 
member 100 above the polyethylene film is measured using a suitable 
displacement measuring system. A suitable displacement measuring system is 
an ONO-SOKKI DG 3610 Digital Gauge and an ONO-SOKKI GS-503 Linear Gauge 
Sensor available from the ONO-SOKKI Corporation of Japan. The Z-direction 
caliper of the lifting member 100 is measured at various Z-direction load 
levels applied to the lifting member 100 through a circular load 
application foot having a diameter of 0.95 inch. The load application foot 
is connected to the linear gauge sensor. 
The lifting member 100 and polyethylene film are placed on the balance, and 
the balance is tared out to have a zero reading. The initial dry 
Z-direction caliper of the lifting member 100 is measured with the load 
application foot just touching the lifting member 100, so that the balance 
indicates a reading of about zero. The Z-direction load on the lifting 
member 100 is increased to 32.1 grams in about 5 equal increments, so that 
the balance indicates a weight of 32.1 grams. The load is then removed, 
and the unloaded dry Z-direction caliper of the lifting member 100 is 
recorded with the load application foot just touching the lifting member 
100, so that the balance indicates a reading of about zero. For each 
sample, the difference between the initial dry Z-direction caliper and the 
unloaded dry Z-direction caliper is divided by the initial dry Z-direction 
caliper to obtain the percentage change in dry caliper of the sample. The 
dry caliper reduction is the average of the percentage change in dry 
caliper for the four lifting member samples. 
Each lifting member (and its associated polyethylene sheet) is completely 
submerged in distilled water for 10 seconds, and then allowed to drain 
vertically for 10 seconds. The lifting member 100 and polyethylene sheet 
are then supported on the horizontal surface of the analytical balance, 
and the balanced tared out to indicate a reading of zero. The initial wet 
Z-direction caliper of the lifting member 100 is measured with the load 
application foot just touching the lifting member 100, so that the balance 
indicates a reading of about zero. The Z-direction load on the lifting 
member 100 is then increased to 32.1 grams in about 5 equal increments. 
The load is then removed and the unloaded wet Z-direction caliper of the 
lifting member 100 is recorded with the load application foot just 
touching the lifting member 100, so that the balance indicates a reading 
of about zero. For each sample, the difference between the initial wet 
Z-direction caliper and the unloaded wet Z-direction caliper is divided by 
the initial wet Z-direction caliper to obtain the percentage change in the 
wet caliper of the sample. The wet caliper reduction of the lifting member 
100 is the average of the percentage change in wet caliper for the four 
lifting member samples. 
In one embodiment, the lifting member 100 is nonabsorbent. By 
"nonabsorbent" it is meant that the lifting member 100 has an absorbency 
capacity of less than 100 percent. The absorbency capacity is the ratio of 
the weight of the water absorbed by a dry sample to the dry sample weight. 
A nonabsorbent lifting member 100 is believed to have the advantage that 
its stiffness and/or its ability to displace the central core segment 62 
upward are relatively unaffected by body fluids entering the absorbent 
article 20, as compared to a lifting member which is absorbent. The 
absorbency capacity of the lifting member is measured by first weighing 
the lifting member 100 to obtain its dry weight, and then completely 
submerging the lifting member 100 in distilled water for 10 seconds. After 
10 seconds the lifting member 100 is removed from the water. The lifting 
member is then allowed to drain vertically for 10 seconds. Water adhering 
to the surface of the lifting member is then removed by blotting the 
lifting member between two pieces of filter paper for 10 seconds. The 
lifting member 100 is blotted by placing a first piece of filter paper on 
a dry horizontal surface, placing the lifting member on the first piece of 
filter paper, placing a second piece of filter paper on top of the lifting 
member to cover the lifting member, and placing a piece of 0.25 inch thick 
Plexiglas weighing 0.26 pound on top of the second piece of filter paper 
to cover the portion of the second piece of filter paper overlying the 
lifting member. A suitable filter paper for blotting the lifting member 
100 is filtration paper having a relatively smooth surface, a particle 
retention size of greater than about 20-25 micrometers, and a Herzberg 
filtration speed of about 37 seconds, where the filtration speed is the 
time for 100 ml of prefiltered water to pass through a 10.0 square 
centimeter piece of filter paper with a constant head pressure of 10 
centimeters of water. A suitable filtration paper is Whatman 4 filtration 
paper manufactured by Whatman Ltd. of England and available from the 
Fisher Scientific Company of Pittsburgh, Pa. After blotting the lifting 
member 100 for 10 seconds, the lifting member 100 is immediately weighed 
to obtain the wet sample weight. The dry weight is subtracted from the wet 
weight to yield the grams of water absorbed by the dry sample. The 
percentage absorbency capacity is obtained by dividing the grams of water 
absorbed by the dry sample weight, and multiplying the quotient by 100. 
In one embodiment the lifting member 100, and particularly the pleats 115, 
is hydrophobic. A surface is hydrophobic if the contact angle between a 
liquid and the surface is greater than 90 degrees. The American Chemical 
Society Publication "Contact Angle, Wettability, and Adhesion," edited by 
Robert F. Gould and copyrighted in 1964 is incorporated herein by 
reference for the purpose of showing how the contact angle can be 
determined. 
In one embodiment the lifting member 100 extends along the longitudinal 
centerline 29 of the sanitary napkin 20, and can have a longitudinal 
length which is approximately equal to the length L of the central core 
segment 62. The lifting member can have a lateral width C (FIG. 1 ), 
corresponding to the width of the second and third members 120 and 130, 
which is less than the lateral width W1 of the central core segment 60. 
Without being limited by theory, a relatively large width C provides 
lateral stability of the lifting member 100, and a relatively small width 
C enhances fit of the raised portions of the topsheet and core with the 
labia, perineum, and gluteal groove areas of the body. 
The first element 110 can be formed from a number of suitable materials, 
including but not limited to woven and nonwoven sheet material, plastic 
films, and natural or synthetic rubber strands. One suitable material from 
which the first element 110 can be formed is a polypropylene mesh scrim 
material having a basis weight of about 100 grams per square meter and 
available as P100 (also designated PC-52) polypropylene mesh scrim from 
Smith and Nephew Plastics, Ltd. of Gilberdyke, North Humberside, UK. A 
sheet of such a mesh scrim has about 16 relatively thicker and stiffer 
primary strands per inch running in the sheet machine direction and about 
24 relatively thinner and less stiff secondary strands per inch running 
perpendicular to the primary strands in the sheet cross machine direction. 
The first element 110 can comprise a 6.0 mm wide strip of the P100 (PC-52) 
mesh cut parallel to the primary strands, so that the primary strands 
extend along the length of the first element 110, and generally parallel 
to the longitudinal axis 29 of the sanitary napkin 20. Another suitable 
material from which the first element 110 can be formed comprises a 
polypropylene mesh scrim having a basis weight of about 50 grams per 
square meter (10 lbs/1000 square feet) available as ON7100 polypropylene 
mesh from the Conwed Company of Minneapolis, Minn. 
The elastic second and third elements 120 and 130 can be formed from a 
number of types of elastic material including natural or synthetic rubber 
strands, elastic woven or nonwoven materials, and elastic films. One 
suitable material from which the second and third elements 120 and 130 can 
be formed is an elastic tape sold by Fulflex, Inc. of Middletown, R.I. as 
ULTRAFLEX Model 6EX29 elastic tape. The second and third elements 120 and 
130 can each comprise a length of such an elastic tape having a width of 
between about 4.0 and 6.0 mm and a thickness of about 2.0 mm. 
Alternatively, the elements 120 and 130 can each comprise a 6.0 mm wide 
strip of EXX-500 elastic sheet material available from the Exxon Chemical 
Company of Buffalo Grove, Ill. A lifting member 100 having a first element 
110 formed of the above PC-52 polypropylene mesh scrim and second and 
third elements 120, 130 formed of the above ULTRAFLEX tape is 
nonabsorbent, and has a wet caliper reduction which is less than about 20 
percent of its dry caliper reduction, with the wet caliper reduction no 
more than about 8 percent. 
The pleats 115 in the first element 110 can be formed by elastic 
contraction of one or both of the second and third elements 120,130 
relative to the first element 110. For instance, the first element 110 can 
have a free (unstretched) length which is greater than the free length of 
the second element 120 and the third element 130. The second and third 
elements 120 and 130 can be elongated relative to their free lengths and 
relative to the first element 110. While elongated, the first and second 
elements 120 and 130 can be attached to the first element 110 at spaced 
apart locations along the length of the first element 110. When the forces 
causing the elongation of the elastic elements 120 and 130 are released, 
the elastic elements 120 and 130 will contract relative to the first 
element 110, thereby drawing the spaced apart attachment points on the 
first element 110 together to form the pleats 115. 
Percentage elongation is determined by subtracting an elongated length from 
the free gage length, and dividing the difference by the free gage length. 
For elastic elements 120 and 130 formed from the ULTRAFLEX elastic tape 
listed above, a suitable lifting member 100 with pleats 115 can be made by 
providing a percentage of elongation in the second and third elements 120 
and 130 of between about 35 and about 400 percent. The second and/or third 
elastic elements 120 and 130 can be attached to the first element 110 at 
locations spaced apart a distance of between about 25.4 mm (1.0 inch) and 
about 127 mm (5.0 inch) as measured when the elastic elements are 
elongated and prior to gathering of the first element 110 by contraction 
of the second and third elements 120 and 130. 
The height H1 of the pleats 115 is at least about 10 mm, preferably at 
least about 15 mm, and more preferably at least about 20 millimeters to 
provide adequate displacement of the central core segment 62 relative to 
the side core segments 64 and 66. In the embodiment shown in FIG. 4 the 
Z-direction height H1 of the pleats 115 is generally uniform along the 
length L of the lifting member 100. By way of example, the height H1 can 
be between about 20 mm to about 22 mm. The spacing L1 between adjacent 
pleats 115 can be between about 15 mm and about 19 mm. For a lifting 
member 100 having a first element formed from the P100 (PC-52) mesh scrim 
material listed above and having first and second elastic elements 120, 
130 formed from the ULTRAFLEX elastic tape listed above, such a uniform 
arrangement of pleats 115 can be obtained where the percentage of 
elongation in the second and third elements 120 and 130 is about 250 to 
about 300 percent and where the second and third elements 120 and 130 are 
attached to the first element 110 at locations spaced apart a distance of 
about 49 mm to about 52 mm as measured when the second and third elements 
120 and 130 are elongated and prior to gathering the first element 110 by 
contraction of the second and third elements 120 and 130. A lifting member 
100 having a first element formed from the above listed P100 (PC-52) mesh 
scrim material and having first and second elastic elements 120, 130 
formed from the above listed ULTRAFLEX tape can have a pleat height H1 of 
22 mm and a spacing L1 of 16 mm where the percentage of elongation of the 
second and third elements 120 and 130 is about 300 percent and where the 
second and third elements are attached to the first element at locations 
spaced apart a distance of about 50 millimeters as measured when the 
second and third elements are elongated. 
While the height H1 is relatively uniform along the longitudinal axis 29 in 
FIG. 4, in other embodiments the Z-direction height of the pleats 115 can 
vary along the longitudinal length L of the lifting member 100. U.S. 
patent application Ser. No. 08/170,461 filed Dec. 20, 1993 in the name of 
McFall is incorporated herein by reference for the purpose of disclosing a 
lifting member 100 having pleats 115 with uniform and varying Z-direction 
heights. 
In another embodiment the lifting member 100 can comprise a wicking member 
for transporting body fluids in the Z-direction and along the length of 
the lifting member 100. For instance, the pleated first element 110 can 
comprise a wicking member and can transport body fluids longitudinally 
along the length of the lifting member 100, and in the Z-direction from 
the central core segment 62 and the wicking member 70 to the support 
member 80. A first pleated element 110 which comprises a wicking member 
can be formed from apertured or nonapertured plastic films, plastic mesh 
scrims, or elastic strands treated or formed to be hydrophilic. A suitable 
first element 110 can be formed from a polypropylene mesh scrim, such as 
the above PC-52 mesh scrim, treated or formed to be hydrophilic. The mesh 
scrim can be treated to be hydrophilic by depositing on its surface a 
layer of hydrophilic meltblown polyethylene fibers, such as are available 
from the Fibertech Corporation of Landisville, N.J. Alternatively, the 
mesh scrim can be formed to be hydrophilic by including in the scrim resin 
additives that bloom to the surface of the scrim and render it 
hydrophilic. One such additive is a Xantrex polypropylene resin available 
from the Himont Company of Delaware. The elastic second and third elements 
120 and 130 can be formed from a variety of hydrophilic apertured 
substrates, including elastomeric films and nonwovens treated or formed to 
be hydrophilic. A suitable material from which the second and third 
elements 120 and 130 can be formed is an elastomeric meltblown nonwoven 
with a basis weight of between about 40 to about 120 grams per square 
meter coated on both sides with a suitable surfactant to make the surfaces 
of the nonwoven hydrophilic. A suitable nonwoven is a thermoplastic 
polyurethane spunbond fabric such as Kanebo Urethane Spunbond available 
from the Kanebo Company of Osaka, Japan. A suitable surfactant with which 
the nonwoven can be treated is SILWET surfactant manufactured by the ICI 
Company of Ostringen, Germany. 
FIG. 10 illustrates an apparatus for forming a pleated lifting member 100 
and joining the lifting member 100 to another component of the sanitary 
napkin 20. In FIG. 10, three continuously fed pieces of material are 
designated as components 1110, 1120, and 1130. By way of example component 
1110 can correspond to the first element 110, component 1120 can 
correspond to the elastic second element 120, and component 1130 can 
correspond to the elastic third element 130. The components 1120 and 1130 
can be bonded to the component 1110 at spaced apart locations along the 
length of the component 1110, such as with an adhesive. The discussion 
below refers to adhesive bonding of the components 1100, 1200 and 1300, 
but it will be understood that other bonding methods can be used. For 
instance, the components can be thermally or ultrasonically bonded 
together. Alternatively, the components can be mechanically bonded 
together in a pressure biased nip between a relief patterned cylinder and 
an anvil cylinder according to the teachings of above referenced U.S. Pat. 
No. 4,919,738 issued Apr. 24, 1990 to Ball et al., which patent is 
incorporated by reference. 
The component 1120 is carried at a first web speed through a first nip 
formed between a first pair of compression rolls 1001, 1003 rotating at a 
first rotational speed. An adhesive applicator 1200 applies adhesive to a 
side of the component 1120 at spaced apart locations after the component 
1120 exits the nip formed by rolls 1001, 1003. A suitable adhesive is 
Findley Adhesive H2031 available from the Findley Adhesive Company of 
Elmgrove, Wis. 
The component 1120, along with component 1110, is then directed into a 
second nip formed by a second pair of compression rolls 1005, 1007. The 
component 1120 is pressed into engagement with the component 1110 by the 
second pair of rolls 1005, 1007 to adhesively bond the components 1120 and 
1110 together at spaced apart locations. The nip rolls 1005, 1007 can be 
chilled to prevent buildup of the adhesive. 
The surface speed of the rolls 1005, 1007 carries the components 1120 and 
1110 through the second nip at a second web speed greater than the first 
web speed at which the component 1120 is carried through the first nip. 
This web speed differential stretches the component 1120, and thereby 
differentially elongates the component 1120 relative to the component 1110 
prior to intermittently joining the component 1120 to the component 1110. 
For example, if the compression rolls have the same diameter, the second 
pair of compression rolls 1005, 1007 can be rotated at a second rotational 
speed which is greater than the first rotational speed of the rolls 1001, 
1003. 
The intermittently joined components 1110 and 1120 exit the second nip and 
are carried around first and second reversing rolls 1011 and 1013 in a 
generally serpentine path. An adhesive applicator 1200 then applies 
adhesive to spaced apart locations on a side of the component 1110 not 
joined to the component 1120. The web speed around the rolls 1011, and 
1013 can be maintained equal to the second web speed to maintain the 
tensile elongation in the component 1120. 
The intermittently joined components 1110 and 1120, along with the 
component 1130, are then directed around a roll 1015 to press the 
component 1130 into engagement with side of the component 1110 to which 
adhesive is intermittently applied. The component 1130 is thereby joined 
to the component 1110 at spaced apart locations. The web speed around the 
roll 1015 can be maintained equal to the second web speed to maintain the 
tensile elongations in the component 1120. 
Prior to being joined to the component 1110, the component 1130 can be 
directed at a third web speed through a third nip formed by a third pair 
of compression rolls 1017, 1019 rotating at a third rotational speed. The 
third web speed can be less than the second web speed at which the 
components 1110, 1120, and 1130 are carried around the roll 1015. This web 
speed differential stretches the component 1130, so that the component 
1130 is differentially elongated relative to the component 1110. If the 
third web speed is equal to the first web speed, the percent elongation of 
the component 1130 will be approximately equal to the percent elongation 
of the component 1120. Alternatively, if the third web speed is less than 
(or greater than) the first web speed, the percent elongation of the 
component 1130 will be greater than (or less than) the percent elongation 
of the component 1120. 
The combined components 1110, 1120, and 1130, along with a component 1150, 
can be directed at a fourth web speed through a fourth nip formed by a 
fourth pair of compression rolls 1021, 1023. The component 1150 can be a 
continuous web comprising one or more of the materials from which the 
backsheet 50 and support member 80 are formed, or alternatively, a 
continuous web comprising one or more of the materials from which the 
topsheet 40, wicking member 70, and central core segment 62 are formed. An 
adhesive applicator 1200 can apply adhesive to a side of the component 
1150 prior to engagement of the component 1150 with the component 1130 in 
the fourth nip. The assembly of components 1110, 1120, 1130, and 1150 can 
be combined in later operations with other sanitary napkin components to 
form a completed sanitary napkin 20. 
The tension in the stretched components 1120 and/or 1130 can be relaxed, 
such as by reducing the web speed before or after the components 1110, 
1120 and 1130 are combined with the component 1150 in the fourth nip. Once 
the tension in the stretched components is relaxed, the stretched 
components will elastically contract relative to the component 1110, and 
thereby gather the component 1110 to form pleats 115. 
A lifting member 100 having pleats 115 with a Z-direction height that 
varies along the length of the lifting member can be formed by varying one 
or more of the web speeds with time. The elongation of the component 1120 
relative to the component 1110 will then vary along the length of the 
intermittently joined components. Once the tension in the component 1120 
is relaxed, the elastic contraction of the component 1120 relative to the 
component 1110 will vary along the length of the intermittently joined 
components, thereby forming pleats 115 having different Z-direction 
heights. The Z-direction height of the pleats 115 can also be varied along 
the length of the lifting member 100 by holding the elongation of the 
component 1120 constant while varying the spacing at which the component 
1120, while elongated, is attached to the component 1110. Alternatively, 
the Z-direction height of the pleats 115 can be varied by varying both the 
elongation of the component 1120 and the spacing at which the elongated 
component 1120 is attached to the component 1110. 
FIG. 11A shows an arrangement for forming a pleated lifting member 100 and 
joining the lifting member 100 to a wicking member 70 and a support member 
80. In FIG. 11A, three continuously fed pieces of material are designated 
as components 2110, 2120, and 2130. By way of example, component 2110 
corresponds to the first element 110 of the lifting member 100, component 
2120 corresponds to the elastic second element 2120, and component 2130 
corresponds to the elastic third element 130. Similarly, continuous webs 
2070 and 2080 in FIG. 11A correspond to the wicking member 70 and the 
support member 80, respectively. 
The component 2120 is laterally supported by a guide 2038. Likewise, the 
component 2110 is laterally supported by a guide 2038. The component 2120 
is carried through a nip formed by a pair of stretching rolls 2005 and 
2007. The rolls 2005 and 2007 are rotated to have a surface speed less 
than that of downstream meter rolls 2025 and 2027 to thereby elongate the 
component 2120. Intermediate the stretch rollers 2005, 2007 and the meter 
rolls 2025, 2027, the components 2110 and 2120 are carried through a nip 
formed by a pair of heat sealing rolls 2015 and 2017. The heat sealing 
rolls 2015, 2017 thermally bond the component 2110 to the elongated 
component 2120 at spaced apart locations along their lengths. The roll 
2017 has a plurality of projections 2018 spaced apart around the 
circumference of roll 2017 to provide the desired bond spacing along the 
components 2110 and 2120. For bonding components 2110 and 2120 comprising 
the above P100 (PC-52) mesh scrim and ULTRAFLEX elastic tape, the surfaces 
of the rolls 2015 and 2017 can be heated to about 300 degrees Fahrenheit, 
and the interference between projections 2018 and roll 2015 can be set to 
zero. The components 2110 and 2120 exit the nip formed by rolls 2015 and 
2017 thermally bonded together, with pleats 115 formed in the component 
2110. 
An adhesive applicator 2028 applies adhesive to the component 2120 after 
the components 2120 and 2110 exit the nip formed by the meter rolls 2025 
and 2027. The adhesive applied by applicator 2028 serves to later bond the 
component 2120 to the component 2070 at downstream bonding rolls 2035 and 
2037. Similarly, an adhesive applicator 2029 applies a coating of adhesive 
to the components 2130 and 2080. The adhesive applied by the applicator 
2029 serves to join the components 2130 and 2080 together as they are 
conveyed adjacent one another, and also serves to later bond components 
2130 and 2080 to the components 2110 and 2070, respectively, at the 
downstream bonding rolls 2035 and 2037. 
Prior to bonding the components at the bonding rolls 2035 and 2037, the 
component 2070 is directed through a folding board 3000. Referring to FIG. 
11B, the folding board 3000 includes a an elevated tongue 3100 and folding 
plows 3200. As the central portion of the component 2070 is carried over 
the tongue 3100 and the sides of the component 2070 are carried under the 
folding plows 3200, parallel folds 2071 are formed in the component 2070 
which correspond to the folds 71 in the wicking member 70. 
After the component 2070 is folded, the components 2110, 2120, and 2130 are 
carried through the nip of the bonding rolls 2035 and 2037 between the 
components 2070 and 2080. The bonding roll 2035 includes a 
circumferentially extending groove 2036 for accommodating the components 
2110, 2120, and 2130 which are sandwiched between the components 2070 and 
2080. The continuous laminate of components exiting the bonding rolls 2035 
and 2037 is cut to the desired length to form individual tissue/lifting 
member laminates 2050, each comprising a support member 80, a wicking 
member 70, and a lifting member 100 disposed between the members 70 and 
80. A cut and slip assembly, such is manufactured by the Curt G. Joa 
Company of Sheboygan Falls, Wis. can used to cut the continuous components 
to the desired length. Such a cut and slip assembly can include a cutting 
roll 2044 and a vacuum drum 2045 for carrying the laminates 2050 to a 
downstream conveyor, at which point the laminates 2050 can be joined to 
one or more other components of the sanitary napkin 20. 
The lifting member 100 shown in FIGS. 1-5 has a longitudinally extending 
pleated element 110. Such a lifting member has the advantage that it can 
be relatively easily manufactured by the continuous process described 
above, and maintains its resiliency even after being compressed for 
extended periods of time (e.g., when the sanitary napkin is packaged prior 
to use.) Of course, other lifting members can be used without departing 
from the scope of the present invention. U.S. patent application Ser. No. 
08/170,487 Sanitary Napkin Having Internal Shaping Component filed Dec. 
20, 1993 in the name of Bergman and U.S. patent application Ser. No. 
7/605,583 Sanitary Napkin Having Components Capable of Separation in Use 
filed Oct. 29, 1990 in the name of Visscher et al. are incorporated herein 
by reference for the purpose of showing components capable of providing 
relative Z-direction displacement of different portions of a sanitary 
napkin. 
The wicking member 70 conveys body exudates from the central core segment 
62 to the first and second side core segments 64 and 66. The wicking 
member 70 can also provide lateral support to the lifting member 100. A 
preferred wicking member 70 comprises one or more webs of cellulosic 
fibers, each web having a basis weight of between about 10 grams per 
square meter and 65 grams per square meter. A particularly preferred 
wicking member 70 comprises a tissue paper web have a basis weight of 
about 42 grams per square meter. The wicking member 70 is preferably made 
according to the teachings of U.S. Pat. No. 4,637,859 issued Jan. 20, 1987 
to Trokhan, which patent is incorporated by reference. 
The support member 80 transfers loads from the lifting member 100 to the 
backsheet 50. The support member 80 preferably has a lateral width greater 
than the lateral width C of the lifting member 100 to distribute loads 
from the lifting member across a portion of the width of the backsheet 50. 
The support member 80 can also convey fluids along its length and width. A 
preferred support member 80 comprises one or more webs of cellulosic 
fibers having a basis weight of between about 10 grams per square meter 
and 65 grams per square meter. A particularly preferred support member 80 
comprises a tissue paper web have a basis weight of about 42 grams per 
square meter. The support member 80 is preferably made according to the 
teachings of above referenced U.S. Pat. No. 4,637,859. 
Referring to the exploded view of FIG. 5, the core segments 62, 64, and 66 
are joined to the secondary topsheet layer 46 by adhesive attachments 169. 
The adhesive attachments 169 can comprise Findley H2031 hot melt adhesive. 
Another suitable adhesive from which attachments 169 can be formed is 
Findley H4031 adhesive available from the Findley Adhesive Company. The 
central core segment 62 is joined to the central portion 72 of the wicking 
member 70 by an adhesive attachment 177, and the side core segments 64 and 
66 are joined to the backsheet 50 by adhesive attachments 179. The 
adhesive attachments 177 and 179 can comprise one of the Findley H2031 or 
H4031 adhesives listed above. 
The second element 120 of the lifting member 100 is joined to the central 
portion 72 of the wicking member 70 by an adhesive attachment 187. The 
side portions 74 and 76 of the wicking member 70 are joined to the side 
portions 84 and 86, respectively, of the support member 80 by adhesive 
attachments 189. The adhesives attachments 187 and 189 can comprise one of 
the above Findley adhesives. The third element 130 of the lifting member 
100 is joined to the central portion 82 of the support member 80 by an 
adhesive attachment 191. The support member 80 is joined to the backsheet 
50 by adhesive attachments 193. The adhesive attachments 191 and 193 can 
comprise one of the above Findley adhesives. 
The Applicants have found that the present invention improves the ability 
of a sanitary napkin to receive and hold body fluids. Applicants have 
found that compared to a sanitary napkin having a single piece airfelt 
core with no lifting member 100, the sanitary napkin 20 shown in FIGS. 1-5 
provides equivalent body fluid holding capacity with a reduced quantity of 
airfelt. In particular, the Applicants found that the sanitary napkin 20 
shown in FIGS. 1-5 having a total of about 4.2 grams of airfelt in the 
core segments 62, 64, and 68 and about 1.4 grams of tissue paper in the 
wicking and support members 70 and 80 provides equivalent fluid holding 
capacity compared to a sanitary napkin having a single piece airfelt core 
weighing about 9.2 grams. 
FIGS. 6 and 7 show alternative embodiments of the present invention. In 
FIG. 6 the wicking member 70 comprises a pair of tissue webs 77 and 79. 
Each of the tissue webs 77 and 79 has a central portion 72 disposed 
intermediate the lifting member 100 and the central core segment 62, and 
first and second side portions 74 and 76. The first side 74 of the tissue 
web 77 can be joined, such as by adhesive, to the first side portion 74 of 
the web 79. Similarly, the second side portion 76 of the tissue web 77 can 
be joined to the second side portion 76 of the web 79. An absorbent 
gelling material 90 is disposed intermediate the central portions 72 of 
the tissue webs 77 and 79. The lifting member 100 displaces the absorbent 
gelling material 90 in the Z-direction relative to the side core segments 
64 and 66. The absorbent gelling material 90 can be adhesively joined to 
one or both of the tissue webs 77 and 79. The absorbent gelling material 
90 serves as a storage zone for body liquids passing through the central 
core segment 62, and increases the liquid holding capacity of the sanitary 
napkin 20 over that which is available in the core segments 62, 64, and 66 
alone. The arrangement shown in FIG. 6 provides the advantage that the 
absorbent gelling material 90 is positioned adjacent the central core 
segment 62, and can thereby rapidly acquire body fluids deposited along 
the longitudinal centerline 29 of the sanitary napkin 20. 
An absorbent gelling material is a material which swells upon wetting and 
absorbs at least about 20 times its weight in water. Such absorbent 
gelling materials include but are not limited to silica gels and organic 
compounds such as crosslinked polymers. Particularly preferred absorbent 
gelling materials are hydrolyzed acrylonitrile grafted starch, acrylic 
acid grafted starch, polyacrylates and isobutylene maleic anhydride 
copolymers, or mixtures thereof. U.S. Pat. No. Re 32,649 reissued to 
Brandt et al. Apr. 19, 1988 is incorporated herein by reference for the 
purpose of showing suitable absorbent gelling materials. 
In FIG. 7 the support member 80 comprises a pair of tissue webs 87 and 89. 
Each of the tissue webs 87 and 89 has a central portion 82 disposed 
intermediate the lifting member 100 and the backsheet 50, and first and 
second side portions 84 and 86. The first side portion 84 of the tissue 
web 87 can be joined, such as by adhesive, to the first side portion 84 of 
the web 89. Similarly, the second side portion 86 of the tissue web 87 can 
be joined to the second side portion 86 of the web 89. An absorbent 
gelling material 90 is disposed intermediate the central portions 82 of 
the tissue webs 87 and 89. The absorbent gelling material 90 can be 
adhesively joined to one or both of the tissue webs 88 and 89. The 
absorbent gelling material 90 serves as a storage zone for body liquids 
conveyed by the wicking member 70 from the central core segment 62. The 
arrangement shown in FIG. 7 provides the advantage that the lifting member 
100 does not lift both the central core segment 62 and the absorbent 
gelling material 90, and the body fluids are contained at a location 
spaced from the wearer's body by the lifting member 100. 
FIGS. 8 and 9 disclose alternate embodiments of the present invention 
wherein the central core segment 62 comprises an acquisition zone 262A 
having a density less than the density of the airfelt first and second 
side core segments 64 and 66. The relatively low density acquisition zone 
262A is positioned in the area of typical fluid deposition to quickly 
acquire and distribute liquids within the sanitary napkin 20. U.S. Pat. 
No. 4,834,735 issued May 30, 1989 to Alemany et al. discloses high density 
absorbent members having lower density acquisition zones, and is 
incorporated herein by reference. The relatively low density acquisition 
zone 262A preferably has a density less than about 0.12 grams per cubic 
centimeter under a confining pressure of 0.1 pounds per square inch. 
Referring to FIG. 8, the acquisition zone 262A is positioned along the 
longitudinal centerline 29 so that the lifting member 100 displaces the 
acquisition zone 262A in the Z-direction relative to the side core 
segments 64 and 66. The acquisition zone 262A is registered with an 
opening 47 in the secondary topsheet layer 46 so that fluids deposited on 
the body facing surface 42 of the topsheet 40 along the longitudinal 
centerline 29 can directly enter the acquisition zone 262A from the 
primary topsheet layer 44. The acquisition zone 262A can be positioned 
intermediate relatively higher density forward and rearward airfelt 
segments 262B and 262C. 
In one embodiment acquisition zone 262A is constructed to transport body 
fluids passing through the opening 47 in a direction generally parallel to 
the longitudinal centerline 29 of the sanitary napkin 20. A portion of the 
body fluids carried from the opening 47 toward the ends 30A and 30B by the 
acquisition zone 262A are then stored in the airfelt segments 262B and 
262C, and the remaining body fluids are transported laterally and in the 
Z-direction by the wicking member 70 for storage in the first and second 
side core segments 64 and 66. 
The acquisition zone 262A can comprise a plurality of longitudinally 
oriented capillary channel fibers 310 for transporting body fluids in a 
direction parallel to the longitudinal centerline 29 of the sanitary 
napkin 20. Portions of the capillary channel fibers 310 registered with 
the opening 47 are preferably bonded to the primary topsheet layer 44, 
such as by adhesive bonding, to enhance transfer of body fluids from the 
topsheet 40 to the acquisition zone 262A. By "longitudinally oriented" it 
is meant that the fibers 310 extend in a direction generally parallel to 
the longitudinal centerline 29 of the sanitary napkin 20. The term 
"capillary channel fiber" refers to a fiber having a cross-section forming 
an open channel passageway for transporting fluid along the length of the 
fiber. The fiber cross-section can comprise a number of different shapes, 
including but not limited to C-shapes, V-shapes, and H-shapes. The 
following documents are incorporated by reference for the purpose of 
disclosing such capillary channel fibers: U.S. Pat. No. 5,281,208 issued 
Jan. 25, 1994 to Thompson et al.; U.S. Pat. No. 5,200,248 issued Apr. 6, 
1993 to Thompson et al; PCT Publication WO 93/02235 Fibers Capable of 
Spontaneously Transporting Fluids published Feb. 4, 1993 in the name of 
Phillips and having a U.S. Priority date of Jul. 23, 1991; and EP 
Application 0391814 Fibers Capable of Spontaneously Transporting Fluids 
published Oct. 10, 1990 in the name of Phillips and having a U.S. Priority 
date of Apr. 4, 1989. 
The acquisition zone 262A can comprise a tow bundle of longitudinally 
oriented capillary channel fibers 310. The term "tow bundle" refers to a 
collection of generally parallel fibers having substantially the same 
fiber length. The tow bundle of capillary channel fibers can have a total 
denier of between about 25,000 to about 60,000 grams per 9000 meters of 
tow length, and can have a total weight of about 0.25 gram to about 1.5 
gram. The capillary channel fibers 310 in the tow bundle are preferably 
located in at least the central third of the sanitary napkin 20 as 
measured along the longitudinal centerline 29, and can extend 
substantially the full length of the absorbent core 60, as shown in FIG. 
8. 
In one embodiment, the tow bundle of capillary channel fibers 310 can have 
a total denier of about 50,000 and a weight of about 1.0 gram. The fibers 
310 can comprise helically crimped polyethylene-terephthalate (PET) fibers 
having a crimping frequency of about 3 crimps per inch, a crimp amplitude 
of about 0.45 mm, and a relatively deep C shaped cross-section having a 
channel width of about 55 micron and a channel depth of about 102 micron, 
with a denier per fiber of about 24 grams per 9000 meters. Such a tow 
bundle of fibers is manufactured by the Eastman Chemical Company of 
Kingsport, Tenn. under the designation 4SW "Deep C" CX Low Crimp Helical 
Tow, SW-405. 
In another embodiment, the tow bundle of capillary channel fibers 310 can 
have a total denier of about 25,000. The fibers 310 can comprise helically 
crimped PET fibers having a crimping frequency of about 2.5 crimps per 
inch, a crimp amplitude of about 0.9 mm, and a C-shaped cross-section 
having a channel width of about 53 microns and a channel depth of about 50 
microns, with a denier per fiber of about 10 grams per 9000 meters. Such a 
tow bundle of fibers is manufactured by the Eastman Chemical Company under 
the designation 4SW "Spread C" CX, Low Crimp Helical Tow, SW407. 
In yet another embodiment, the acquisition zone 262A can comprise a carded 
sliver of staple fibers having a total denier of about 60,000 grams per 
9000 meters of sliver length. The fibers of the carded sliver are 
longitudinally oriented and can have a 6 inch staple fiber length and a 
fiber denier of about 27 grams per 9000 meters of fiber length. The fibers 
can be helically crimped PET fibers with a crimping frequency of about 6 
crimps per inch, a crimp amplitude of about 0.5 mm, and an H-shaped 
cross-section having a channel width of about 43 microns, a channel depth 
of about 61 microns, and a denier per fiber of about 27 grams per 9000 
meters. Such a carded sliver is manufactured by the Eastman Chemical 
Company under the designation 4SW "H" CX, Carded Staple Sliver, SW404. 
In yet another embodiment the acquisition zone 262A can comprise 
cross-linked cellulosic fibers. U.S. Pat. No. 5,183,707 issued Feb. 2, 
1993 to Herron et al. is incorporated by reference for the purpose of 
disclosing cross-linked cellulosic fibers suitable for use in forming the 
acquisition zone 262A. 
In the embodiment shown in FIG. 9, the acquisition zone 262A comprises a 
tow bundle of longitudinally oriented capillary channel fibers 310 
disposed between bonded fiber layers 320. The tow bundle of capillary 
channel fibers 310 is joined to the bonded fiber layers 320 by any 
suitable means, including but not limited to adhesive bonding and 
ultrasonic bonding. The bonded fiber layers 320 serve to rapidly acquire 
body fluids, and the tow bundle of longitudinally oriented capillary 
channel fibers 310 distributes the acquired body fluids in the 
longitudinal direction. 
The tow bundle of capillary channel fibers 310 can have a total denier of 
about 25,000 and comprise PET fibers having a C-shaped cross-section with 
a channel width of about 50 microns and a channel depth of about 99 
microns, with a denier per fiber of about 22 grams per 9000 meters. Such a 
tow of fibers is manufactured by the Eastman Chemical Company under the 
designation 4 SW "Deep C" CX, Uncrimped Tow, SW406. The tow bundle of 
capillary channel fibers 310 can have a total weight of about 0.5 grams. 
The bonded fiber layers 320 comprise a bonded network of capillary channel 
fibers and bicomponent binder fibers. The bonded network can comprise 
about 90 percent by weight capillary channel fibers and about 10 percent 
by weight bicomponent binder fibers. The bicomponent binder fibers can be 
thermoplastic binder fibers such as DANAKLON ES C 1.7 dtex.times.6 mm 
crimped bicomponent binder fibers. The capillary channel fibers of the 
bonded fiber layers 320 can be helically crimped, staple length PET fibers 
having a C-shaped cross-section and a staple length of about 1.5 inch. The 
capillary channel fibers can have a crimp frequency of about 7.5 crimps 
per inch, a crimp amplitude of about 0.4 mm, a channel width of about 52 
microns, and a channel depth of about 47 microns. Such fibers are 
manufactured by the Eastman Chemical Company under the designation SW408. 
The bonded layers 320, combined, can include about 0.45 grams of the 
capillary channel fibers and about 0.05 grams of the bicomponent binder 
fibers. The network of fibers can be formed and thermally bonded as 
described in U.S. patent application Ser. No. 08/141,156 Catamenial 
Absorbent Structures Having Thermally Bonded Layers for Improved Handling 
of Menstrual Fluids, and Their Use in Catamenial Pads Having Improved Fit 
and Comfort filed Oct. 21, 1993 in the name of Richards et al., which 
patent application is incorporated herein by reference. The bonded layers 
320 can have a density of about 0.02 to about 0.06 gram per cubic under a 
confining pressure of about 0.1 pounds per square inch, and a basis weight 
of between about 15 to about 45 grams per square meter. 
In another embodiment the bonded layers 320 can have a basis weight of 
about 30 grams per square meter, a density of about 0.035 gram per cubic 
centimeter under a confining pressure of about 0.1 pounds per square inch, 
and a Z-direction thickness of about 0.8 mm under a 0.1 pound per square 
inch confining pressure. The bonded layers 320 can comprise about ninety 
percent by weight PET capillary channel fibers and about 10 percent by 
weight bicomponent binder fibers. The binder fibers can comprise DANAKLON 
ES C 1.7 dtex .times.6 mm bicomponent fibers. The capillary channel fibers 
can have a denier per fiber of 22 grams per 9,000 meters, a crimp 
frequency of 3.6 crimps per inch, a crimp amplitude of about 0.29 mm, a 
channel width of about 49 microns, and a channel depth of about 97 
microns. Such fibers are manufactured by the Eastman Chemical Company 
under the designation SW376. 
While particular embodiments of the present invention have been illustrated 
and described, the scope of the present invention is defined by the 
appended claims.