Fastening film system and assembly comprising a fastening film system and a substrate

The present invention relates to a fastening film system 1 comprising a backing 7 and an adhesive layer 6 on one of the two major surfaces of the backing 7, the backing 7 bearing on its exposed major surface 3a opposite to the adhesive layer 6 a plurality of male fastening elements 4 capable of engaging with fibrous materials 32 having a plurality of complementary female fastening elements, and a plurality of through-holes 2 extending through the thickness 11 of the backing 7 so that the adhesive layer 6 attached to the backing 7 is exposed through such through-holes 2 wherein at least one of said through-holes 2 is encompassed by the backing 7, and wherein the fastening film system 1 releasably adheres to said fibrous materials 32 through a combination of a mechanical and an adhesive bonding mechanism.

FIELD OF THE INVENTION

The present invention relates to a fastening film system which is suitable for releasably adhering to fibrous materials through a combination of a mechanical and an adhesive bonding mechanism. The present invention furthermore relates to methods of preparing such fastening film systems and to disposable absorbent articles such as diapers or sanitary napkins employing such fastening film systems.

BACKGROUND OF THE INVENTION

EP 0,321,232 discloses a disposable absorbent article such as a diaper comprising a pair of tape tabs attached to an end region of said diaper. Each of the tape tabs exhibits on its respective user's end a fastening surface which has one or two exposed rectangular adhesive areas adjacent to a rectangular strip of a hook fastening element. This construction provides a combination of a mechanical and an adhesive closure mechanism when attaching the tape to the landing member thereby securing the diaper to the wearer's body.

EP 0,974,326 also discloses a disposable absorbent article such as a diaper having a pair of tape tabs attached to a first end region of said diaper and a landing member attached to a second end region of said diaper whereby the user's end of the tape tab comprises both mechanical and adhesive fastening means. It is disclosed that the exposed adhesive area of the tape tab may become contaminated with fiber elements when adhering the tape tab to the fibrous landing member. EP '326 discloses a release treatment of the exposed surface of the fibrous landing member in order to minimize or avoid, respectively, damaging of the fibrous landing member and/or contamination of the exposed adhesive area on the tape tabs.

Fastening film systems providing both a mechanical and an adhesive fastening mechanism are also disclosed in U.S. Pat. Nos. 6,393,673, 6,428,525, 6,402,730,

WO 99/06,600 and EP 0,418,951. U.S. Pat. No. '673, for example, describes a mechanical fastening element comprising a multiplicity of flexible hook elements emanating from a backing layer and comprising stems terminating in hook heads wherein the top portions of the hook heads and/or at least part of the interstitial spaces between the stems are coated with a hot-melt pressure-sensitive adhesive.

U.S. Pat. No. 4,959,265 discloses a pressure-sensitive adhesive tape fastener comprising a backing having an array of upstanding stems distributed across at least one face, and a pressure-sensitive adhesive layer filling the spaces between the stems where the average thickness of the adhesive layer is less than the average height of the stems. When adhering the pressure-sensitive adhesive tape fastener to a sanitary napkin, the napkin can be releasably attached to an undergarment by allowing the stems to penetrate into openings of the fabric of the undergarment until the pressure-sensitive adhesive becomes releasably bonded to the fabric.

Attaching the fastening film systems disclosed in U.S. Pat. Nos. 6,393,673, 6,428,525, 6,402,730, WO 99/06,600, EP 0,418,951 and U.S. Pat. No. 4,959,265 to a disposable absorbent article such as a sanitary napkin usually requires providing an additional adhesive layer onto the surface of the fastening film system opposite to the surface bearing the male fastening elements, which may be less advantageous.

Disposable absorbent articles such as sanitary napkins, panty liners and incontinence pads, comprising mechanical and adhesive fastening means arranged separately from each other on different portions of the disposable absorbent article, are known. U.S. Pat. No. 5,676,652 discloses, for example, sanitary napkins comprising adhesive strips on the garment side of the main body of the sanitary napkin and mechanical fasteners on the side wrapping elements. U.S. Pat. No. 5,611,790 discloses sanitary napkins having adhesive fastening means, mechanical fastening means or combinations of adhesive and mechanical fastening means which are arranged separately from each other in patches, for example, on the garment side of the main body of the napkin or on the side wrapping elements.

Sanitary napkins, for example, need to be capable of reliably and releasably adhering to a variety of natural or synthetic fibrous materials such as cotton, silk, nylon, woven, non-woven, knitted and/or microfibrous materials without damaging such materials. These requirements are fulfilled by the sanitary napkins available in the state of the art to an insufficient extent only.

It was therefore an object of the present invention to provide a fastening film system which is capable of releasably adhering to a variety of fibrous materials through a combination of a mechanical and an adhesive bonding mechanism and which does not exhibit the shortcomings of the fastening surfaces of the state of the art or exhibits them to a lower degree only, respectively. Other objects of the present invention will be readily derivable form the following detailed description.

SUMMARY OF THE INVENTION

The present invention relates to a fastening film system comprising a backing and an adhesive layer on one of the two major surfaces of the backing, the backing bearing on its exposed major surface opposite to the adhesive layer a plurality of male fastening elements capable of engaging with fibrous materials having a plurality of complementary female fastening elements, and a plurality of through-holes extending through the thickness of the backing so that the adhesive layer attached to the backing is exposed through such through-holes wherein at least one of said through-holes is essentially completely encompassed by said backing, and wherein the fastening film system releasably adheres to said fibrous materials through a combination of a mechanical and an adhesive bonding mechanism.

The present invention furthermore relates to an assembly comprising a substrate and a fastening film system wherein the adhesive layer of the fastening film system is arranged between the backing of the fastening film system and the substrate.

The present invention furthermore relates to a method of making a fastening film system comprising providing a continuous backing bearing a plurality of male fastening elements, providing a plurality of through-holes extending through the thickness of the backing wherein at least part of said through-holes is essentially completely encompassed by said backing, and laminating the resulting backing onto an adhesive layer.

The present invention furthermore relates to another method of making a fastening film system of the present invention comprising providing a continuous backing bearing a plurality of male fastening elements, providing one or 2n+1 continuous cuts with n being an integer in the machine direction, into the backing so that the cut which has a periodic sequence of notches and protrusions characterized by a wavelength and an amplitude, forms the 2 or 2n adjacent sub-backings, separating the 2 or 2n adjacent sub-backings by about at least the amplitude in the cross-direction and by about half of the wavelength or a multiple of such half of the wavelength, respectively, in the machine direction, and moving the 2 or 2n sub-backings towards each thereby creating a sequence of through-holes between the two sub-backings which are at least partly encompassed by the backing, and attaching an adhesive layer to the surface of the sub-backings opposite to the surface bearing a plurality of male fastening elements.

The present invention furthermore relates to a method of making an assembly of the present invention comprising providing a substrate and applying an adhesive layer to an exposed surface of such substrate, providing a continuous backing bearing on one of its major surfaces a plurality of male fastening elements, further providing a plurality of through-holes extending through the thickness of the backing, and attaching the resulting backing comprising through-holes through its major surface which is opposite to the major surface bearing a plurality of male fastening elements, to the exposed surface of the adhesive layer.

The present invention furthermore relates to another method of making an assembly of the present invention comprising providing a substrate and applying an adhesive layer to an exposed surface of such substrate, providing a continuous backing bearing on one of its major surfaces a plurality of male fastening elements, providing one or 2n+1 continuous cuts with n being an integer, in the machine direction into the backing so that the cut which has a periodic sequence of notches and protrusions characterized by a wavelength and an amplitude, forms 2 or 2n adjacent sub-backings, separating adjacent sub-backings by about at least the amplitude in cross-direction and by about half of the wavelength or a multiple of such half of the wavelength, respectively, in the machine direction, and moving the 2 or 2n sub-backings towards each other thereby creating a sequence of through-holes between the two sub-backings, and attaching the resulting construction of sub-backings through the major surfaces of such sub-backings which are opposite to the major surfaces bearing a multitude of male fastening elements, to the exposed surface of the adhesive layer.

The present invention furthermore relates to a disposable absorbent article such as a diaper or a sanitary napkin comprising a liquid-permeable top sheet, a liquid-impermeable back sheet opposite to said top sheet, a liquid-absorbent core between said top sheet and said back sheet, longitudinal edges, a first end region and a second end region, the absorbent article further comprising the fastening film system or assembly according to the present invention in order to secure said disposable absorbent article to the body and/or to the undergarment or panties of a person.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a fastening film system1comprising a backing7having two major surfaces3aand3b. The term “film” as used above and below indicates that the fastening film system1has extensions in two directions termed as the machine direction (MD) and the cross-direction (CD) which independently from each other distinctly exceed the extension of such fastening film system1in a third direction normal to MD and CD, respectively. The term “system” as used above and below is intended to indicate that the fastening film system1comprises at least a backing7and an adhesive layer6.

The term “machine direction” (MD) as used above and below denotes the direction of the running, continuous web of the backing7during the manufacturing of the fastening film system1. In the embodiment of the continuous web of backing7shown inFIG. 3a, the machine direction corresponds to the direction of the longitudinal edges of the web of the backing7. The term “cross-direction” (CD) as used above and below denotes the direction which is essentially normal to the machine direction.

The exposed major surface3aof the backing7of the fastening film system1of the present invention bears a plurality of male fastening elements4capable of engaging with fibrous materials32having a plurality of complementary female fastening elements. An adhesive layer6is attached to the major surface3bof the backing7of the fastening film system1opposite to its exposed major surface3a. The backing7furthermore comprises a plurality of through-holes2exposing the adhesive of adhesive layer6thereby providing an adhesive bonding mechanism to said fibrous materials32in addition to the mechanical bonding mechanism effected by the male fastening elements4.

The backing7preferably is an essentially flat continuous film that may be formed by cast molding or extrusion molding. Substantially any thermoplastic material suitable for film production can be used to produce the backing. Preferred thermoplastic resins include polyesters such as poly(ethylene terepthalate), polyamides such as nylon, poly(styrene-acrylonitrile), poly(acrylonitrile-butadiene-styrene), polyolefins such as polypropylene, and plasticized polyvinylchloride.

The exposed major surface3aof the backing7preferably is essentially flat but it may also exhibit a pattern and the thickness11of the backing7may, for example, be higher in areas adjacent to the through-holes2as compared to areas between the through-holes2.

The backing7may comprise only one material and exhibit an essentially uniform construction in CD, but it may also comprise a sequence of two or more zones in CD having different properties whereby such zones preferably extend continuously in MD.

The thickness11of backing7which is essentially flat or the effective thickness of a backing which is not essentially flat, in the areas adjacent to the through-holes2, respectively, preferably is between 10 μm and 1 mm, more preferably between 12 μm and 800 μm and especially preferably between 15 μm and 750 μm. If the thickness is above 1 mm, the interaction between the adhesive area exposed through the through-holes2and a fibrous material32being brought into contact with the fastening film system1tends to be too weak so that no or an insufficient adhesive bonding mechanism is present between the fastening film system1and such fibrous material32. If the thickness11of the backing7is less than 10 μm, the adhesive bonding mechanism tends to dominate the interaction between the fastening film system1and such fibrous material32to such an extent that especially lofty fibrous materials32may be damaged upon separating and rebonding the fastening film system1to the substrate. If the thickness of the backing7is less than 10 μm, the mechanical stability of the backing7bearing male fastening elements4also tends to be too low.

The exposed major surface3aof the backing7exhibits a plurality of male fastening elements4. The male fastening elements preferably have a hook shape, and they usually comprise a stem4asupported by the exposed major surface3aof the backing7and an enlarged section4bwhich is positioned at the end of the stem opposite to the exposed major surface3aof the backing7. The male fastening elements4can also be formed by stems4ahaving no enlarged section at the end of the stern4aopposite to the backing whereby such stems4apreferably are essentially conical, cylindrical or pyramidal.

The male fastening elements4preferably are integral with the exposed major surface3aof the backing7but it is also possible that the male fastening elements4are bonded individually or in form of patches each having a support layer bearing one or more male fastening elements4to the exposed major surface3aof the backing7. Bonding of such individual fastening elements4or patches of fastening elements4, respectively, can be effected, for example, by adhesive bonding, by ultrasonic bonding, by thermal bonding or by stitching. It is disclosed, for example, in WO 00/50,229 to apply discrete hook patches to the exposed surface3aof a backing7.

The enlarged section4bof the male fastening elements4may have any shape such as hooks, T's, J's, mushroom-type heads (including concavely curved heads and disc-shaped heads) or any other shape allowing for engagement with complementary female fastening elements.

Male fastening elements4suitable in the present invention can be manufactured from a wide range of materials including thermoplastic polymers such as, for example, nylon, polyester, polyolefins or any combination of these. The male fastening elements4preferably comprise the material of which the backing7is formed.

The dimensions of the individual male fastening elements4can be varied widely depending on the application and the structure and loftiness of the complementary female fibrous material32. When employing the fastening film system1of the present invention, for example, in disposable sanitary articles such as incontinence articles, diapers or napkins, the male fastening elements4comprising stems4aand, optionally, an enlarged section4bat the end of the stem opposite to major surface3a, preferably are between 40 μm and 2 mm in height above the backing. The stems4apreferably have a cross-section with a maximum extension of between 10 μm and 250 μm. The ratio of the maximum extension of the enlarged portions4bof the male fastening elements4at the end of the stems4aopposite to the exposed major surface3aof the backing7, over the maximum extension of the cross-sections of the stems4apreferably is between 1.5:1 and 5:1.

The average surface density of the male fastening elements4with respect to the total surface area of the backing7(including the surface area of through-holes2) may vary broadly and preferably is between 10/cm2and 5,000/cm2, more preferably between 20/cm2and 4,000/cm2and especially preferably between 25/cm2and 3,500/cm2. If the density of the male fastening elements4is less than 10/cm2the strength of the mechanical bonding mechanism between the fastening film system1and a fibrous material32brought into contact with the fastening film system1, tends to be insufficient for practical purposes. If the density of the male fastening elements4is above 5,000/cm2, the single fastening elements4tend to be very small and may not mechanically engage with the fibrous material32sufficiently.

A preferred mushroom-type hook web including a homogenous backing7of thermoplastic resin and, integral with the backing7, an array of upstanding stems4aprojecting from the surface3aof the backing7and having a mushroom head4bat the end of the stem4aopposite to the surface of the backing7, is disclosed, for example, in U.S. Pat. No. 5,077,870. This mushroom-type hook strip can be obtained by feeding the molten thermoplastic resin through a die to a rotating cylindrical mold which has cavities that are negatives of the upstanding stems4a. The molten resin is injected into the cavities in an excess of an amount that would fill the cavities so that a backing7is formed. The resin is solidified and then stripped from the mold as a web that has an array of upstanding stems4a. The web is then passed between two calendar rolls whereby the roll contacting the tip of the stems4ais heated to allow for formation of the mushroom heads4b. U.S. Pat. No. 5,679,302 discloses another mushroom-type hook strip where the enlarged portion4bat the end of the stems is essentially disc-shaped.

Male fastener webs comprising a homogenous backing7and, integral with the backing7, an array of male fastening elements4whereby the enlarged portions4bhave a variety of shapes, is disclosed, for example, in U.S. Pat. No. 4,894,060.

The male fastener webs and the specific geometry of the individual fastening elements4disclosed in U.S. Pat. Nos. 5,077,870, 5,679,302 and U.S. Pat. No. 4,894,060 are described here only by way of example and are not intended to limit the invention in any way. Other non-limiting examples of suitable male fastener webs are described, for example, in U.S. Pat. No. 4,984,339 and U.S. Pat. No. 5,781,969.

The backings7exhibit a plurality of through-holes2which can be obtained, for example, by die-cutting, punching, cutting or stretching, or they may be formed directly when manufacturing the fastener web. The through-holes2extend throughout the thickness11of the backing7, i.e., they connect two openings one opening being in the exposed major surface3aof the backing7bearing a plurality of male fastening elements4and the other opening being in the major surface3bof the backing7opposite to its exposed major surface3a. The two openings are arranged so that they partly overlap in a direction normal to MD and CD, i.e., an observer viewing at the backing in a direction normal to MD and CD can look through the through-holes2. The through-holes2can also be formed by two adjacent parts of a backing7,7′ as is shown inFIG. 1d.

The through-holes2preferably extend essential normal to the MD and the CD as is shown, for example, inFIG. 1bbut it is also possible that the through-holes2extend in a direction oblique to the direction which is normal to MD and CD. The effective cross-section of a through-hole2is the area seen by an observer when viewing at the backing in a direction normal to MD and CD. The sum of such areas is referred to above and below as the surface area of the through-holes2.

The ratio of the surface area of the through-holes2relative to the surface area of the backing7(prior to cutting, i.e. the surface area of the backing7including the surface area of the through-holes2) preferably is between 15 and 85%, more preferably between 20 and 75% and especially preferably between 35 and 65%.

The average value of the maximum effective extension of the through-holes2preferably is between 1 and 50 mm, more preferably between 1 and 40 mm and especially preferably between 1 and 35 mm. The term maximum effective extension refers to the maximum possible distance between two points of the effective cross-section of through-holes2as seen by an observer viewing in a direction normal to CD and MD.

If the average value of the maximum effective extension of the through-holes2is less than 1 mm, the exposed adhesive of such through-holes2tends not to form a sufficient adhesive bonding mechanism between the fastening film system1and a fibrous material32brought into contact with the fastening film system1. If the average value of the maximum effective extension of the through-holes2is more than 50 mm, the adhesive bond between the fastening film system1and fibrous materials32tends to be too strong which may result in damaging said fabric, in particular, lofty, fibrous materials32.

The average surface density of through-holes2, i.e. the average number of said through-holes2per surface unit, preferably is between 100/m2and 40,000/m2, more preferably between 250/m2and 20,000/m2and especially preferably between 250/m2and 17,500/m2.

The average distance between adjacent through-holes2preferably is at least 1 mm, more preferably at least 1.2 mm and especially preferably at least 1.5 mm. If the average distance between two adjacent through-holes is less than 1 mm, the adhesive bonding mechanism between the adhesive exposed through such through-holes2and a fibrous material32brought into contact with the fastening film system1tends to be too high for many applications. Furthermore, if the average distance between two adjacent through-holes2is less than 1 mm, the surface density of the male fastening elements4tends to be too low. The average distance between adjacent through-holes2preferably is less than 15 mm, more preferably less than 10 mm and especially preferably less than 8 mm.

The effective cross-section of the through-holes2may exhibit various shapes such as, for example, circular, rectangular, triangular, ellipsoid, essentially trapezoid or more complicated regular or irregular shapes.

The through-holes2may be completely or partly encompassed by the backing7. Through-holes2which are only partly encompassed by the backing7may be present, for example, at the edges of a piece of a fastening film system1as is illustrated, for example, inFIG. 1a. It is also possible, for example, that the fastening film system1comprises an exposed adhesive strip continuously extending in MD as is illustrated inFIG. 1d. InFIG. 1d, the exposed adhesive strip and the through-holes arranged at the edges of the two parts of a backing7,7′ form through-holes2which are not fully encompassed by the backing7,7′ whereas the other through-holes of the fastening film system1ofFIG. 1dare fully encompassed by the backing7,7′.

It is exemplified inFIG. 3a-3dthat two sub-webs7a,7beach having a plurality of partly encompassed through-holes2defined by cuts8, may be rearranged into an adjacent placement to form a plurality of essentially completely encompassed through-holes2.

It is essential in the present invention that at least one of the through-holes2, preferably at least 50/m2, more preferably at least 100/m2and especially preferably at least 150/m2, are completely encompassed by the backing7. The ratio of the number of through-holes2which are completely encompassed by the backing7over the total number of through-holes2preferably is at least 0.5, more preferably at least 0.75 and especially preferably at least 0.8.

It was found by the present inventors that a well balanced combination of an adhesive and a mechanical bonding mechanism with respect to a variety of fibrous materials32can only be obtained if at least one of the through-holes2is fully encompassed by the backing7. If no fully encompassed through-holes2are present, the adhesive bonding mechanism of the fastening film system1or the assembly40, respectively, towards various fibrous materials32as evaluated, for example, by the measurement of the 90° peel adhesion values referred to below, may differ distinctly so that fibrous materials32experiencing a strong adhesive interaction with the respective fastening film system1or the assembly40, respectively, may be damaged as a result of such strong adhesive interaction. It was also found that fastening film systems of the present invention comprising at least one fully encompassed through-hole2, tend to exhibit a lower value of the adhesive bonding mechanism in comparison to a fastening film system comprising the same surface area of the through-holes relative to the surface area of the backing7prior to cutting but no fully encompassed through-holes2. Because of such better control of the adhesive bonding mechanism, damaging of the fibrous material32is less likely.

It was furthermore found by the present inventors that a well-balanced combination of an adhesive and a mechanical bonding mechanism with respect to a variety of fibrous materials32can be obtained if the sum of the maximum densities of the through-holes2along the extension of the backing7and/or the adhesive layer6in the CD and in the MD preferably is at least 1 cm−1, more preferably at least 1.3 cm−1and especially preferably at least 1.5 cm−1. Such embodiments of the fastening film system1and the assembly40are especially preferred.

In order to determine such maximum density in the CD and in the MD, the maximum number of through-holes2in such directions is determined as is schematically indicated inFIG. 1cfor the portion of the fastening film ofFIG. 1a.

When applying a dotted auxiliary line, for example, in the CD and shifting it parallel to the CD along the extension of the fastening film system1, it is easily established that the maximum number of through-holes2in the CD is3; this can be seen, for example, when counting the number of through-holes2in the CD along the dotted line included inFIG. 1c. Likewise, when applying a dotted auxiliary line in the MD so that it intersects or touches, respectively, as many through-holes as possible, it is easily established that the maximum number of through-holes2in the MD is3(seeFIG. 1c). The dotted lines are imaginary auxiliary lines only and they are included inFIG. 1cfor determining the maximum number of through-holes in the CD and in the MD, respectively.

The maximum densities in the CD and in the MD are obtained by dividing these numbers by the respective extension of the adhesive layer6in the CD and in the MD, respectively. These densities are then summed up.

The major surface3bof the backing7opposite to its exposed major surface3a, bears an adhesive layer6which may be continuous or discontinuous. The adhesive layer6extends on the major surface3bof the backing7(at least partly) in the area of the through-holes2so that the adhesive which is present in the area of the through-holes2is exposed. The average ratio of the exposed area of the adhesive layer6over the surface area of the through-holes2preferably is at least 0.75, more preferably at least 0.9 and especially preferably essentially 1.0.

The adhesive of adhesive layer6is preferably selected from a group of adhesives having a 90° peel adhesion to a smooth polyethylene test surface as measured according to ASTM D3330F using a roll-down weight of 5,000 g, of between 1 N/inch and 10 N/inch, more preferably of between 1.5 N/inch and 8 N/inch and especially preferably of between 2 N/inch and 8 N/inch. If the 90° peel adhesion is less than 1 N/inch, the adhesive bonding mechanism between the fastening film system1and a fibrous material32brought into contact with it, tends to be undesirably low in many cases. Also, for such low values of 90° peel adhesion, it tends to be difficult to optimize the performance of the fastening film system1with respect to a variety of fibrous materials32including both lofty-type fabrics such as cotton based fabrics or more densely woven fabrics such as, for example, nylon based fabrics. If the 90° peel adhesion is higher than 10 N/inch, the adhesive bonding mechanism between the fastening film system1and a fibrous material32brought into contact with it, tends to be undesirably strong in many cases so that the fibrous material32may be damaged. Tacky adhesives which are useful in the present invention preferably include pressure-sensitive adhesives which are selected from a group comprising (meth)acrylate and/or natural or synthetic rubber-based pressure-sensitive adhesives. Rubber-resin additives preferably comprise in addition to the rubber materials one or more tackifying resin in order to render the rubber materials tacky. Preferred examples of rubber-based pressure-sensitive adhesives are the polystyrene-polyisoprene block copolymers tackified with synthetic polyterpene resins. Suitable acrylate-based pressure-sensitive adhesives are disclosed, for example, in U.S. Re 24,906 or U.S. Pat. No. 4,710,536. Suitable synthetic rubber based adhesives are described, for example, in U.S. Pat. No. 5,019,071 and U.S. Pat. No. 3,932,328.

The adhesive layer6may be applied to the major surface3bof the backing7opposite to its exposed major surface by lamination. When preparing an assembly40according to the present invention, the adhesive layer6is preferably first applied to an exposed surface of a substrate5by coating or lamination, and the backing7is then applied to the adhesive layer6through its major surface3b.

The dimensions of the adhesive layer6in CD and/or MD may essentially match with the corresponding dimensions of the backing7but it is also possible that the dimensions of the adhesive layer6in CD and/or MD differ and, in particular, exceed the dimensions of the backing7. The assembly40shown inFIGS. 2aand2band inFIG. 6b, for example, comprises adhesive layer6the dimensions of which exceed the dimensions of the corresponding backing7.

The through-holes2are preferably introduced into the backing7prior to applying the adhesive layer6but it may also be possible to introduce the through-holes subsequently to the application of the adhesive layer6by kiss-cutting.

The backing7may be subjected to monoaxial or biaxial stretching prior to or subsequent to the application of the adhesive layer6, respectively. Monoaxial stretching can thus be applied to the backing7, to the fastening film system1or to the assembly40, respectively, in MD or CD, and biaxial stretching can be applied to the backing7, to the fastening film system1or to the assembly40, respectively, subsequently or simultaneously in CD and MD. The term stretch ratio as used above and below denotes the ratio of a linear dimension of a given portion of the stretched backing7, the fastening film system1or the assembly40, respectively, to the linear dimension of the same portion of the backing7, the fastening film system1or the assembly40, respectively, prior to stretching. The stretch ratios in MD and CD preferably are independently from each other between 1.1:1 and 8:1 and more preferably between 1.1:1 and 5:1. Biaxial stretching is preferred. Monoaxial stretching or sequential biaxial stretching can be performed, for example, by propelling a continuous web of the backing7, the fastening film system1or the assembly40, respectively, in the respective direction over rollers of increasing speed. Simultaneous biaxial stretching can be performed, for example, by using a flat film tenter apparatus as is described, for example, in U.S. Pat. Nos. 4,675,582, 4,825,111, 4,853,602, 5,036,262, 5,051,225 and U.S. Pat. No. 5,072,493.

Stretching which can be applied to a backing7prior to introducing the through-holes2or to a backing7comprising through-holes, to the fastening film system1or to the assembly40, respectively, effects various parameters of the backing7, the fastening film system1or the assembly40such as, for example, the thickness of the backing7, of the adhesive layer6and of the substrate5, the shape and/or the density of the male fastening elements4, and the shape and the average value of the maximum effective extension of the through-holes2. The person skilled in the art can select the stretch ratio and the mode of stretching, i.e., monoaxial or biaxial stretching, to vary and optimize such parameters within the preferred ranges as specified above.

In another preferred embodiment of the present invention, the backing7comprising through-holes2may be an extrusion-formed reticulated web, mesh or netting comprising two sets of strands at angles to each other. A preferred method of making such nettings includes extruding a thermoplastic resin through a die plate which is shaped to form a base film layer having a first set of spaced supporting ridges or ribs projecting from one major surface of the base layer film and a second set of ridges or nibs exhibiting a cross-sectional profile of a male fastening element4such as a hook projecting from the other major surface of the base film layer. The spaced supporting ridges or ribs formed on one major surface of the base film layer form the first set of strands forming the reticulated mesh or netting. The second set of transverse strands are formed by transversely cutting the opposite major surface of the base film layer comprising the second set of ridges or ribs, to form discrete cut members. Subsequently longitudinal stretching of the backing layer in the direction of the first set of the supporting ridges or ribs, i.e., in MD, separates these discrete cut portions. The cut portions then form the second set of spaced-apart strands bearing male fastening elements4such as hooks that have a cross-sectional shape identical to the cross-sectional shape of the second set of nibs or ridges.

The two sets of spaced-apart strands obtained in such method form the backing7bearing male fastening elements4, and the openings in the mesh or netting structure form the through-holes2. The dimensions of the supporting ridges or ribs and the spacing between adjacent supporting ridges or ribs is preferably selected to provide sufficiently large through-holes2. The dimension of the through-holes2is influenced by the spacing between adjacent ridges or ribs of the first set of supporting ridges or ribs, by the spacing between the cut-lines through the second set of ridges or nibs having, for example, a hook-shaped cross-section and by the stretching ratio of longitudinal stretching in MD.

The person skilled in the art can select and modify these parameters to vary and optimise the dimension of the through-holes2and the adjacent areas of the backing7, respectively.

Mesh or netting structures and methods of preparing them are disclosed, for example, in the co-pending patent application U.S. Ser. No. 10/376,979 filed by the present applicant on 28 Feb. 2003 with the U.S. Patent and Trademark Office. It is also possible on all or preferably on part of the exposed major surface3aof the backing7, that the enlarged sections4bof the male fastening elements and/or the interstitial spaces between the stems4aof the male fastening elements4comprise a pressure-sensitive adhesive. In this case, the adhesive bonding mechanism is provided through the adhesive on and/or between the male fastening elements on the exposed major surface3aof the backing7and through the adhesive layer6exposed through the through-holes2. This construction allows to further modify and tailor-make the ratio of the adhesive bonding mechanism relative to the mechanical bonding mechanism.

In a preferred embodiment of the present invention the fastening film system1of the present invention forms part of an assembly40which additionally comprises a substrate5. The fastening film system1is preferably attached through its adhesive layer6to an exposed surface of the substrate5.

The substrate5may be formed by a variety of materials and constructions. In one preferred embodiment the substrate5is a disposable absorbent article such as a sanitary napkin20a. The fastening film system1is preferably attached, through its adhesive layer6, to the back sheet22of such sanitary napkin20awhich is facing the wearer's garment during use.

In another preferred embodiment the substrate5is formed by the support film34of a tape tab27which may be used in a disposable absorbent article such as a diaper20b. As is illustrated, for example, inFIG. 6a, the tape tab27may form part of the closure system of a diaper20bcomprising a pair of such tape tabs27and the landing zone28comprising a fibrous material32. In the specific construction shown inFIG. 6bthe support layer bears a continuous adhesive layer6which is used in the manufacturer's end27aof the support film34to secure the tape tab27, for example, to the back sheet22of the diaper20b. In the user's end27bof the support film, the backing7comprising through-holes2and bearing male fastening elements4on its exposed major surface3a, is attached through its opposite major surface3bto the adhesive layer6thereby forming an assembly40.

The support film34may comprise only one material and exhibit an essentially uniform construction in CD but it may also comprise a sequence of two or more zones in CD having different properties whereby such zones preferably extend continuously in MD.

The term “zone” as used above and below refers to a section of the support film34in CD exhibiting an essentially uniform construction and/or uniform properties. The different zones can be formed by different materials which are joined to each other, for example, by adhesive means such as pressure-sensitive adhesive means, ultrasonic bonding, thermal bonding, mechanical bonding, stitching or any combination of these bonding methods. It is, however, also possible that different zones are created by “activating” one or more zones of the web. As used above and below, the term “activating” means subjecting the support film34, for example, to a mechanical, thermal, electrical and/or chemical treatment in order to impart different functionalities to the treated zones of the web.

The different zones of the support film34may consist essentially of one material but it is also possible that the zones comprise a sequence of two or more layers of materials and/or exhibit substructures in the direction essential normal to MD and CD.

One or more zones of the support film34preferably comprise a carrier film in order to impart structural integrity and/or stiffness to the support film in CD. The carrier film may be selected from a variety of films or sheetings including single- or multilayered films, coextruded films, laterally laminated films or films comprising foam layers. The layers of such films or sheetings may comprise various materials such as, for example, polypropylene, polyvinylchloride, polyethylene terephthalate, polyethylene, polyolefin copolymers or blends of polyolefins such as, for example, a blend of polypropylene, LPDE (Iow density polyethylene) and/or LLDPE (linear low density polyethylene), textiles, and non-woven and foamed materials. The thickness of the carrier film is preferably between 30 and 500 μm and more preferably between 40 and 150 μm. The base weight of the backing is preferably between 15 and 500 g/m2, more preferably between 20 and 300 g/m2and especially preferably between 20 and 200 g/m2.

The different zones of the support film34may consist essentially of one material but it is also possible that the zones comprise a sequence of two or more layers of materials and/or exhibit substructures in the direction essential normal to MD and CD.

One or more zones of the support film34preferably comprise a carrier film in order to impart structural integrity and/or stiffness to the support film in CD. The carrier film may be selected from a variety of films or sheetings including single- or multilayered films, coextruded films, laterally laminated films or films comprising foam layers. The layers of such films or sheetings may comprise various materials such, as for example, polypropylene, polyvinylchloride, polyethylene terepthalate, polyethylene, polyolefin copolymers or blends of polyolefins such as, for example, a blend of polypropylene, LPDE (low density polyethylene) and/or LLDPE (linear low density polyethylene), textiles, and non-woven and foamed materials. The thickness of the carrier film is preferably between 30 and 500 μm and more preferably between 40 and 150 μm. The base weight of the backing is preferably between 15 and 500 g/m2, more preferably between 20 and 300 g/m2and especially preferably between 20 and 200 g/m2.

One or more zones of the support film34may comprise one or more elastically extensible materials extending in at least one direction when a force is applied and returning to approximately their original dimension after the force is removed.

Elastically extensible materials which are useful in the present invention include materials which preferably are elastically extensible without requiring an activation step. Such materials include elastic, natural or synthetic rubber, rubber foams, elastomeric scrims, woven or non-woven elastomeric webs, elastomeric composites, zero-strain stretch laminates or prestrained stretch laminates.

The elastically extensible materials may be made from a group of materials comprising essentially isotropic or essentially anisotropic materials, respectively. Useful elastic materials preferably exhibit an elongation at break as measured according to ASTM D 882 in the preferred direction of stretchability of at least 25% or more and, more preferably, of more than 50% and most preferably of more than 100%.

Preferred essentially isotropically elastic materials include elastomeric polyurethane materials, or natural or synthetic rubber materials such as, for example, ethylene-propylene-dien copolymers (EPDM), styrene-butadiene-styrene block copolymers (SBS) or styrene-(ethylene-butylene)-styrene block copolymers (SEBS). Elastomeric materials of the A-B or A-B-A block copolymer type which are useful in the present invention, include, for example, those described in U.S. Pat. Nos. 3,265,765, 3,562,356, 3,700,633, 4,116,917 and U.S. Pat. No. 4,156,673. Other elastomeric materials which may be used to form the elastic means include elastomeric polyamide materials and elastomeric polyolefin and polyester materials. Blends of these elastomers with each other or with modifying non-elastomers are also contemplated. For example, up to 50 wt. %, but preferably less than 30 wt. % with respect to the mass of the elastomeric material can be added as stiffening aids such as polyvinylstyrenes, polystyrenes, polyesters, epoxies, polyolefins or coumarone-indene resin. These stiffening aids tend to improve the flexibility of the elastomeric materials.

Preferred elastic materials are commercially available from Exxon Mobil Corp. under the trademark Vector and from Kraton Polymers Comp. under the trademark Kraton.

Additionally or alternatively it is also possible to subject one or more zones of the support film34to an activation treatment in order to render such zones elastically extensible and/or to increase such elastic extensibility, respectively. Preferred activation treatments include, for example, MD or CD stretching, ring rolling, embossing, thermoforming, high pressure hydraulic forming or casting. Elastomeric laminates comprising at least one non-elastomeric skin layer and at least one core layer where the laminate is treated to exhibit preferential activation regions and non-preferential activation regions so that the preferential activation regions can be stretched to an elastic state, are disclosed in EP 0,521,388. This elastomeric laminate can be used in the support film34of the assembly40of the present invention.

The support film34may comprise further materials such as, for example, stiffening materials, coloured films, printings or registered marks. The support film34may also impart further functionalities such as breathability or differential stiffnesses to the assembly40.

Stiffening materials include, for example, thermally or sonically structured surfaces or additional layers or coatings applied to the support film34.

The support film34preferably has a Gurley stiffness value both in CD and MD as evaluated according to TAPPI Standard Test T 543 om-94, of less than about 1,000 milligrams (mg). The Gurley stiffness both in CD and MD preferably is less than 500 mg and especially preferably less than 200 mg.

The support films34suitable for use in the tape tab27of a diaper20bor in a sanitary napkin20aare described as illustrative examples of substrate5only but are not intended to be limiting in any way. The substrate5may be formed by any article or construction having an exposed surface capable of adhering to adhesive layer6of the fastening film system1.

The dimensions of the substrate5in CD and/or MD may essentially match with the corresponding dimensions of the backing7or the fastening film system1but it is also possible that the dimensions of the substrate5in CD and/or MD differ from and, in particular, exceed the corresponding dimensions of the backing7or the fastening film system1as is shown, for example, inFIGS. 2aand2b.

The fastening film systems1according to the present invention may be obtained by several methods. In the first step of a first embodiment of such method, a backing7bearing a plurality of male fastening elements4is provided. The male fastening elements4are preferably integral with the exposed major surface3aof the backing7. The manufacture of such backings is disclosed, for example, in U.S. Pat. Nos. 5,077,870, 5,679,302 and U.S. Pat. No. 4,894,060. Such backings7are also commercially available, for example, from 3M Company, St. Paul, Minn., USA, under the trade designations CS-200, CS-600 and CS-1010.

In the second step of such method, through-holes2are introduced into such backing, for example, by passing a continuous web of such backing7by a die-cutting station or between appropriately designed rotary cut knives. Any method of die-cutting, laser cutting or punching the through-holes2into the backing7can be applied.

In the third step of such method, an adhesive layer6such as an unsupported pressure-sensitive adhesive layer is provided and laminated to the major surface3bof the backing7opposite to its exposed major surface3abearing the male fastening elements4, thus providing a fastening film system1according to the present invention. The fastening film system1thus obtained can then be wound upon itself, optionally together with a siliconized release film, and stored in the form of a roll. The adhesive layer6preferably is an unsupported adhesive layer but it can also be formed by one of the two adhesive layers of a double-coated adhesive tape comprising a carrier film bearing two adhesive layers.

In the first step of a second embodiment of preparing fastening film systems1, a backing7is provided bearing a plurality of male fastening elements4.

In the second step of such method, one or more continuous cuts8are applied in MD to the backing7. The cuts which can be applied to the backing7by passing it between rotary cut knives, are periodic and exhibit a wavelength8aand an amplitude8bas is shown, for example, inFIG. 3a. The shape of the notches9and protrusions10thus obtained, can vary broadly and preferred embodiments include, for example, sinusoid shapes or a regular sequence of rectangular or trapezoid notches9and protrusions10. A regular sequence of trapezoid incisions is depicted, for example, inFIG. 3a. It is also possible that the notches9and protrusions exhibit a more complicated shape comprising two or more sub-notches and/or two or more sub-protrusions.

In the third step of such method, two adjacent sub-backings7a,7bprovided by such continuous cuts8are separated by a distance exceeding the maximum amplitude8bin the CD and by a distance essentially equal to half of the wavelength8a/2 or a multiple of8a/2, respectively, in the MD. The number of sub-backings7a,7bobtained depends on the number of cuts8which are applied to the backing7. Since an even number of sub-backings is required, i.e. 2, 4, 6, etc. sub-backings7a,7b, an odd number of cuts8, i.e. 1, 3, 5, etc. cuts8, needs to be applied correspondingly.

When shifting two adjacent sub-backings7a,7btowards each other in CD, through-holes2are formed which may be essentially completely encompassed by the backing as is schematically illustrated inFIG. 3d. Depending on the shape of the notches9and protrusions10, it is, for example, also possible to provide a sequence of completely encompassed and not completely encompassed through-holes2, respectively.

In the fourth step of such method, two adjacent sub-backings7a,7bas obtained in step3are laminated to an adhesive layer6so that through-holes are formed which are at least partly encompassed by the backing7. A piece of the resulting fastening film system1obtained by cutting the sub-backings7a,7bin CD is shown inFIG. 3d.

The assembly40of the present invention comprising a fastening film system1and a substrate5may be obtained by several methods.

In the first step of a first method of preparing an assembly40, an adhesive layer6is applied to an exposed surface of the substrate5. The adhesive layer6may be applied, for example, by coating or spray-coating a solution of the adhesive in an appropriate solvent such as, water, MEK or aceton with subsequent drying. It is also possible to coat a partially cured precursor of the adhesive which preferably is solvent-free, to such exposed surface of the substrate5with subsequent curing, optionally in an inert atmosphere of nitrogen and/or argon, for example. The degree of polymerization of the precursor is selected to provide for an appropriate coating viscosity as is disclosed, for example, in U.S. Pat. No. 4,181,752. It is also possible to apply the adhesive layer6by hot-melt coating, screenprinting, rotary screenprinting or by lamination of an adhesive layer. The adhesive layer6preferably is an unsupported adhesive layer but it can also be formed by one of the two adhesive layers of a double-coated adhesive tape comprising a carrier film bearing two adhesive layers.

The dimensions of the adhesive layer6in CD and/or MD may essentially match with the corresponding dimensions of the backing7but it is also possible that the dimensions of the adhesive layer6in CD and/or MD differ and, in particular, exceed the dimensions of the backing7. The assemblies40shown inFIGS. 2aand2band inFIG. 6b, for example, comprise adhesive layers6the dimensions of which exceed the dimensions of the corresponding backing7.

In the second step of such method, a backing7bearing on one of its major surfaces a plurality of male fastening elements4is provided.

The male fastening elements4are preferably integral with the exposed major surface of the backing7. The manufacture of such backings is disclosed, for example, in U.S. Pat. Nos. 5,077,870, 5,679,302 and U.S. Pat. No. 4,894,060. Such backings7are also commercially available, for example, from 3M Company, St. Paul, Minn., USA, under the trade designations CS-200, CS-600 and CS-1010.

In the third step of such method, through-holes2are introduced into such backing7, for example, by passing a continuous web of such backing7by a die-cutting station or between appropriately designed rotary cut knives. Any method of die cutting, laser cutting or punching the through-holes2into the backing7can be applied.

In the fourth step of such method, the backing7comprising through-holes2is attached with its major surface3bwhich is opposite to its major surface3abearing a plurality of male fastening elements4, to the exposed surface of adhesive layer6. The assembly40thus obtained comprises a fastening film system1comprising a backing7with through-holes2and an adhesive layer6, and a substrate5.

In the first step of a second method of preparing an assembly40, a fastening film system1is prepared by any of the methods disclosed above and attached in a second step of such method through the exposed surface of the adhesive layer6to an exposed surface of the substrate5.

From the above methods of preparing fastening film systems1and assemblies40, respectively, the first method of preparing an assembly40which includes applying of an adhesive layer6to an exposed surface of the substrate5with subsequent application of a backing7having through-holes2through the major surface3bof the backing7, to the exposed a surface of the adhesive layer6, is especially preferred. A backing7comprising through-holes2is especially preferably obtained by the methods exemplified inFIG. 3a-3d.

The fastening film system1and the assemblies40, respectively, obtained in any of the preceding methods provide a combination of an adhesive and a mechanical bonding mechanism when brought into contact with fibrous materials32. Fibrous materials32exhibit a structure comprising loops, tangled fibers or openings which form female bonding elements with which the male bonding elements4on the exposed major surface of the backing7of the fastening film system1can interact.

Fibrous materials32which are especially preferred for use in the present invention include woven, knitted and nonwoven materials and mixed fabrics comprising any of the preceding materials. The fibrous material32preferably has a basis weight of less than 350 g/m2, more preferably of less than 300 g/m2and especially preferably of less than 250 g/m2. The fibrous material32may comprise materials which are selected from a group comprising cotton, nylon, silk, polyester and polyethylenes such as polypropylene.

Suitable processes for making webs of nonwoven materials include but are not limited to airlaying, spunbonding, spunlacing, bonding of melt blown web and bonding of carded webs.

Spunbond nonwoven webs are made by extruding a molten thermoplastic as filaments from a series of fine die orifices in a spinneret. The diameter of the extruded filaments is rapidly reduced under tension by, for example, non-eductive or eductive fluid-drawing or other known spunbond mechanisms, such as described in U.S. Pat. Nos. 4,340,563, 3,692,618, 3,338,992, 3,341,394, 3,276,944, 3,502,538, 3,502,763 and U.S. Pat. No. 3,542,615. The spunbond web is preferably bonded (point or continuous bonding).

The nonwoven web layer may also be made from bonded carded webs. Carded webs are made from separated staple fibers, which fibers are sent through a combing or carding unit which separates and aligns the staple fibers in the machine direction so as to form a generally machine direction-oriented fibrous nonwoven web. However, randomizers can be used to reduce this machine direction orientation. Once the carded web has been formed, it is then bonded by one or more of several bonding methods to give it suitable tensile properties. One bonding method is powder bonding wherein a powdered adhesive is distributed through the web and then activated, usually by heating the web and adhesive with hot air. Another bonding method is pattern bonding wherein heated calender rolls or ultrasonic bonding equipment are used to bond the fibers together, usually in a localized bond pattern though the web can be bonded across its entire surface if so desired. Generally, the more the fibers of a web are bonded together, the greater the nonwoven web tensile properties.

Airlaying is another process by which fibrous nonwoven webs useful in the present invention can be made. In the airlaying process, bundles of small fibers usually having lengths ranging between about 6 to about 19 millimeters are separated and entrained in an air supply and then deposited onto a forming screen, often with the assistance of a vacuum supply. The randomly deposited fibers are then bonded to one another using, for example, hot air or a spray adhesive.

Meltblown webs may be formed by extrusion of thermoplastic polymers from multiple die orifices, which polymer melt streams are immediately attenuated by hot high velocity air or steam along two faces of the die immediately at the location where the polymer exits from the die orifices. The resulting fibers are entangled into a coherent web in the resulting turbulent airstream prior to collection on a collecting surface. Generally, to provide sufficient integrity and strength, meltblown webs must be further bonded such as by through air bonding, heat or ultrasonic bonding as described above.

The fibrous material32which may be used in the landing zone28of diapers20bcomprises, for example, knitted loop, velour-type loop or extrusion-bonded nonwoven loop materials. Such materials are commercially available from 3M Company, St Paul, Minn., USA.

Undergarments and pieces of underwear31typically comprise fibrous materials32which may be woven, knitted or nonwoven. The fibrous materials used in undergarments include, for example, cotton, silk, nylon, polyester and polyolefin such as polypropylene.

It was surprisingly found that the fastening film system1and the assembly40of the present invention exhibit an advantageous balance of the adhesive and mechanical bonding mechanism to a variety of fibrous materials32.

The term “mechanical bonding mechanism” as used above and below includes any interaction between the male fastening elements4arranged on the major surface3aof the backing7, and the fibrous material32including, for example, 90° peel adhesion, hang shear adhesion or any frictional interaction.

The term “adhesive bonding mechanism” as used above and below includes any interaction between the adhesive layer6exposed through the through-holes2, and the fibrous material32including, for example, 90° peel adhesion, hang shear adhesion and any frictional interaction.

The fastening film systems1of the present invention can preferably be employed in disposable absorbent articles20such as, for example, sanitary napkins20aor diapers20b.

The term sanitary napkin20aas used above and below refers to an article which is worn by females adjacent to the pudential region that is intended to absorb and contain the various exudates which are discharged from the body (e.g. blood, menses and urine). The term sanitary napkin20ais also meant to include light weight incontinence pads for adults. Sanitary napkins20atypically have a top sheet21which provides a liquid pervious body-contacting surface and a back sheet22which provides a liquid impervious garment surface. The top sheet21and the back sheet22sandwich an absorbent core23providing the means for absorbing menses and other body fluids. The top sheet21is intended to be worn adjacent to the body of the wearer. The back sheet22of the sanitary napkin is on the opposite side and is intended to be placed adjacent to the wearer's undergarments when the sanitary napkin20ais worn.

The present invention, however, is not limited to the particular types or configurations of sanitary napkins20adescribed in the above references.

The sanitary napkins20aaccording to the present invention differ from prior art constructions in that one or more fastening film systems1or assemblies40, respectively, are applied to the back sheet22and/or other parts of the sanitary napkin20a, such as the side wrapping elements30contacting the wearer's undergarments during use. In a preferred embodiment, an adhesive layer6is applied to the back sheet22of the sanitary napkin20awhich forms a substrate5. Subsequently, a backing7comprising through-holes2is attached through its major surface3bto the adhesive layer6thereby forming an assembly40comprising the sanitary napkin as a substrate5, and the adhesive layer6and backing7as a fastening film system1. The ratio of the exposed major surface3aof the backing7relative to the surface area of the backing7and/or the side wrapping element30preferably is between 0.15 and 1.0 and more preferably between 0.25 and 1.0.

The fastening film system1provides an attachment means for securing the sanitary napkin20ato the wearer's undergarments or panties during use. It was surprisingly found that sanitary napkins20aaccording to the present invention can be reliably secured to a variety of undergarments comprising various fibrous materials32such as woven, knitted or nonwoven materials comprising, for example, cotton, silk, nylon, polyester, polyolefin such as polypropylene or a mixture of any of the preceding material. The sanitary napkins20aof the present invention develop a good overall bond strength to a variety of fibrous materials32and simultaneously exhibit a good balance of the adhesive and mechanical bonding mechanism so that the sanitary napkin20ais reliably secured to various types of undergarments without damaging, for example, undergarments with—compared to cotton based materials—a relatively low degree of loftiness by an excessive adhesive bonding strength. Materials with a relatively low degree of loftiness include, for example, silk or nylon based materials whereas cotton based materials typically have a higher degree of loftiness. The loftiness of a fibrous material depends on various parameters including the type and physical characteristics of its fibers and/or filaments and the method of web forming.

The sanitary napkins20aof the present invention are thus characterized by an increased wearer's comfort. Due to the advantageous balance of adhesive and mechanical bonding properties of the fastening film systems1and assemblies40of the present invention, the sanitary napkins20acan also be stacked upon each other without requiring, for example, a release-treated interlayer.

The fastening film system1of the present invention can also be used in disposable absorbent incontinence articles such as diapers20b. Incontinence articles and diapers may have any desired shape such as, for example, a rectangular shape, an I shape, a T shape or an essentially hourglass shape.

FIG. 6ais a schematic exploded view of a specific embodiment of a diaper20bhaving an essentially hourglass shape. The diaper comprises an absorbent core between a liquid pervious top sheet21contacting the wearer's skin, and a liquid impervious back sheet22facing outwardly. The diaper20bhas a first end region25having two tape tabs27arranged at the two longitudinal edges24a,24bof the diaper20b. The tape tabs27are secured through their manufacturer's end27ato the first end region25. When attaching the diaper20bto a wearer's body, the user's ends27bof the tape tabs27each comprising a fastening film system1of the present invention are attached to the target area28comprising fibrous material32which may be arranged on the back sheet22of the second end region26. Examples of loop tapes which may be applied to the target area28to provide an exposed fibrous material, are disclosed, for example, in EP 0,754,415, EP 0,693,889, EP 0,341,998 and EP 0,539,504. In an alternative construction, the back sheet22comprises a woven or non-woven fibrous layer which is capable of interacting with the user's ends27bof the tape tabs27each comprising a fastening film system1or assembly40of the present invention so that no separate target area is required. Such back sheets22are disclosed, for example, in U.S. Pat. No. 6,190,758 and U.S. Pat. No. 6,075,179.

FIG. 6cis a schematic exploded view of another preferred embodiment of a diaper20bwhere a large area tape tab27is used comprising a fastening film system1of the present invention. In the construction ofFIG. 6cthe back sheet22is capable of interacting with the fastening film system1via a combination of a mechanical and an adhesive bonding mechanism so that a separate target area28is not required.

FIG. 6dshows a schematic exploded view of another specific embodiment of a diaper20bwhere a large area tape tab27comprising a fastening film system1is used in conjunction with two landing zones28comprising a fibrous material32. The tape tab27and the target areas28are arranged along the longitudinal edges24a,24bof the first and second end region25,26.

The tape tab27allows to releasably and refastenably attach the diaper20baround the wearer's body.FIG. 6bshows a schematic cross-section of tape tab27comprising a manufacturer's end27afor securing it to the diaper20band a user's end27bcomprising the fastening film system1or the assembly40, respectively. The user's end is gripped by the user when attaching the diaper20bto the wearer. The manufacturer's end27acorresponds to the part of the tape tab27which is fixed or secured to the diaper20bduring the manufacture of the diaper20b; it usually extends from one of the lateral edges (i.e. the edges in cross-direction) of the tape tab27to the longitudinal edges24a,24bof the diaper20b. The user's end27bcorresponds to the part of the tape tab27which is not anchored to the diaper20bduring manufacture; it usually corresponds to the part of the tape tab27which is different from the manufacturer's end27a.

During manufacturing or when the diaper20bis stored prior to use, the user's end27bof the tape tab27is usually folded over onto the top sheet21as is shown, for example, tor one of the two tape tabs27in the diaper20bofFIG. 6a. It is important during the manufacturing of the diaper20bthat the user's end27bdoes not pop open but is releasably secured to the top sheet21of the diaper20b. This so-called “anti-flagging feature” of the tape tab27is provided by the exposed surface of the fastening film system1or assembly40of the tape tab27which provides a combination of a mechanical and an adhesive bonding mechanism. When the diaper20bhas been used or soiled, it is typically rolled up after use and discarded whereby it is convenient to secure the diaper20bin the rolled-up state to avoid spillage of excrements. This so-called “disposal feature” is also provided by the exposed surface of the fastening film system1or the assembly40of the tape tab27which provides a combination of a mechanical and an adhesive bonding mechanism.

The tape tab27may comprise a support film34in addition to the fastening film system1, which may bear, be bonded to or integrally include, respectively, functional components such as, for example, elastic means, fingerlifts, release tapes to provide a Y-bond between the diaper20band the tape tab27, or cover films33. The support film34and the functional components attached to or incorporated into it, respectively, are selected to impart advantageous properties such as, for example, elasticity, breathability or differential stiffness in machine or cross-direction, respectively, to the tape tab27. The support film34is described above in same detail.

Further details on diapers20band their construction are described in literature and may be taken, for example, from U.S. Pat. No. 5,399,219, WO 96/10,382 or EP 0,529,681. Examples for the construction of tape tabs27are given, for example, in WO 99/03,437, EP 0,321,232 or U.S. Pat. No. 5,399,219.

The diaper20bof the present invention differs from prior art constructions in that the user's end27bof the tape tab27comprises a fastening film system1. In a preferred embodiment, an adhesive layer6is applied to the support film34which forms a substrate5. Subsequently, a backing7comprising through-holes2is attached through its major surface3bto the adhesive layer6thereby forming an assembly40comprising the support film34as a substrate5, and the adhesive layer6and the backing7as a fastening film system1.

It was found that the tape tab27of the present invention has an advantageous combination of an adhesive and mechanical bonding mechanism so that it can be repeatedly opened and re-affixed essentially without damaging the fibrous material32arranged, for example, on the landing zone28or on the back sheet22, respectively.

DETAILED DESCRIPTION OF THE FIGURES

FIG. 1a shows the top view of a fastening film system1comprising a backing7bearing on its exposed major surface3aa plurality of male fastening elements4and exhibiting a plurality of through-holes2at least part of which are fully encompassed by the backing7. The backing7furthermore bears on its major surface3bopposite to said exposed major surface3aan adhesive layer6which is exposed in the areas of the through-holes2.

FIG. 1bis a cross-section along the line1b-1bthrough the fastening film system1ofFIG. 1a. The fastening film system1comprises a backing7exhibiting on its major surface3bwhich is opposite to the exposed major surface3aof the backing, a continuous adhesive layer6. The backing7comprises on its exposed major surface3aa multitude of mushroom-type male fastening elements4each comprising a stem4asupported by the backing7and an enlarged section4bat the end of the stem4aopposite to the backing7. The backing furthermore exhibits through-holes2through which the adhesive layer6is exposed.

FIG. 1cis a reproduction ofFIG. 1awhich additionally comprises two auxiliary dotted lines which are used to determine the maximum number of through-holes2of the piece of fastening film system1ofFIG. 1in the CD and in the MD.

FIG. 1dshows the top view of a fastening film system1comprising two pieces of backing7,7′ bearing on their exposed major surfaces3aa plurality of male fastening elements4and exhibiting a plurality of through-holes2. The backing7,7′ furthermore bears on its major surface3bopposite to said exposed major surface3aan adhesive layer6which is exposed in the areas of the through-holes2. The fastening film system1comprises through-holes2which are fully encompassed by the backing7,7′ and also—at the edge of the backing7,7′ and as a strip of exposed adhesive between the two backings7,7′—through-holes2which are not fully encompassed by the backing7,7′.

FIG. 2ashows the top view of an assembly40of the present invention comprising a fastening film system1and a substrate5. The fastening film system1comprises a backing7exhibiting on its exposed major surface3aa plurality of male fastening elements4and having a plurality of through-holes2. An adhesive layer6is arranged on the major surface3bof the backing7which is opposite to said exposed major surface3a. The adhesive layer6is exposed in the area of the through-holes2. The surface of the adhesive layer6which is opposite to the surface of the adhesive layer6exposed through through-holes2, is attached to an exposed surface of a substrate5. In the embodiment ofFIG. 2a, the dimensions of the adhesive layer6exceed the dimensions of the backing7and the dimensions of the substrate5exceed the dimensions of both the adhesive layer6and the backing7.

FIG. 3ashows the top view of a backing7extending continuously in MD which bears a plurality of male fastening elements4. A periodic cut8having a wavelength8aand an amplitude8bhas been provided in MD thereby creating a sequence of notches9and protrusions10, respectively, and separating the backing7into two sub-backings7aand7b.

FIG. 3bshows the top view of the two continuous sub-backings7a,7bofFIG. 3awhich have been separated in CD by a distance which is greater than the amplitude8bof the cut8(Δ>8b).

FIG. 3cshows the top view of the continuous sub-backings7a,7bofFIG. 3bwhereby the sub-backing7ahas been shifted with respect to sub-backing7bby half of the wavelength8a/2 of the cut8in MD. The position of the sub-backing7aprior to shifting is indicated in dotted lines.

FIG. 3dshows the top view of a piece of a continuous fastening film system1comprising the continuous sub-backings7a,7bofFIG. 3dwhereby an adhesive layer6which is exposed through the through-holes2, is attached to the major surface3bof the backing7opposite to its exposed major surface3abearing the male fastening elements4. The piece of the fastening film system1was obtained from the continuous web of the fastening film system1by cutting in CD.

FIG. 4is a plot of the average 90° peel adhesion per 40 mm between the assembly40of Example 1 and a cotton and a nylon fabric, respectively, as a function of the ratio of the surface area of the through-holes2and the surface area of the backing7prior to applying through-holes2. The surface area of the through-holes2corresponds to the surface area of the adhesive exposed through the through-holes2.

FIG. 5is a plot of the average 90° peel adhesion per inch between the assembly40of Example 3 and a cotton and a nylon fabric, respectively, as a function of the ratio of the surface area of the through-holes2and the surface area of the fastening film system1. The surface area of the through-holes2corresponds to the surface area of the adhesive exposed through the through-holes2.

FIG. 6ais a schematic exploded view of a disposable diaper20bcomprising a top sheet21and a back sheet22sandwiching an absorbent core23. The diaper20bhas a first end region25comprising a pair of tape tabs27which are secured to the diaper20badjacent to longitudinal edges24a,24band which comprise a fastening film system1having a plurality of male fastening elements4and through-holes2. The diaper has a second end region26comprising a fibrous material32on the landing zone28. The tape tabs27are secured to the diaper20bthrough the manufacturer's end27awhile the user's end27bis attached to the fibrous material32when securing the diaper20bto the body of a wearer. The diaper20bcomprises an elastic material in the crotch region29(not shown).

FIG. 6bis a cross-section along the line6b-6bthrough the tape tab27attached to the first end region25of the diaper20bofFIG. 6a. The tape tab27comprises a support film34bearing adhesive layer6which is exposed at the manufacturer's end of the tape tab27. At the user's end27bof the tape tab27, the adhesive layer bears a backing7comprising on its exposed major surface3aa multitude of male fastening elements4and through-holes2through which the adhesive layer6is exposed. The backing7and the adhesive layer6form a fastening film system1of the present invention, and the backing7, the adhesive layer6and the support film34form an assembly40of the present invention. The tape tab27furthermore optionally comprises a cover film33covering adhesive layer6in the remaining part of the user's end27badjacent to the manufacturer's end27a. The outer end of the support film34at the user's end exceeds the extension of the backing7and the adhesive layer6thereby providing a fingerlift35.

FIG. 6cis a schematic exploded view of another preferred embodiment of a diaper20bcomprising two large area tape tabs27which are arranged along the longitudinal edges24a,24bof the first end region25of the diaper. The tape tabs27comprise a fastening film system1of the present invention which interacts with the back sheet22of the diaper20bcomprising an exposed fibrous material.

FIG. 6dis a schematic exploded view of another preferred embodiment of a diaper20bcomprising two large area tape tabs27each comprising a fastening film system1of the present invention, and two target areas28each comprising an exposed fibrous material32. The tape tabs and the target areas28, respectively, are arranged along the longitudinal edges24a,24bof the diaper20b.

FIG. 7ais a schematic exploded view of a disposable sanitary napkin20abeing attached to a piece of undergarment31. The napkin20ahas a liquid pervious top sheet21and a liquid impervious back sheet22sandwiching an absorbent core23. The napkin20afurthermore comprises side wrapping elements30adjacent to its longitudinal edges24a,24bwhich can be folded over when applying the napkin20ato the wearer's piece of underwear31. A fastening film system1comprising a multitude of through-holes2and mechanical fastening elements4is arranged on the back sheet22of the sanitary napkin20aso that the major surface3aof the backing7is exposed. The sanitary napkin20a, the adhesive layer6and the backing7comprising through-holes2form an assembly40of the invention.

FIG. 7bis a schematic top view of a specific embodiment of a sanitary napkin20acomprising side wrapping elements30attached to the back sheet22of the sanitary napkin20a. The wrapping elements each bear on their garment side fastening film system1comprising a backing7and an adhesive layer6which is exposed through the through-holes2of the backing7. The backing7furthermore comprises a multitude of male fastening elements4which are arranged on the exposed surface3aof the backing7.

FIG. 7cis a schematic top view of a specific embodiment of a sanitary napkin20awhere the backing7covers all of the back sheet22of the sanitary napkin. The back sheet22is beneath the backing7and therefore cannot be seen inFIG. 7c. The through-holes2exhibit different geometries along the extension of the back sheet22in MD to provide a variation of the bonding mechanism to a fibrous substrate32(not shown inFIG. 7c) along such direction.

The present invention will now be further illustrated by the following Examples which are intended to illustrate the invention without limiting it

Test Methods

The 90° peel adhesion was measured according to ASTM D 3330 F using a roll-down weight of 5,000 g.

Hang Shear Adhesion

A sample of the fibrous material32against which the fastening film system1or the assembly40, respectively, of the present invention was to be tested, was mounted onto a steel plate with a double-coated adhesive tape. A 40 mm×50 mm piece of the fastening film system1or the assembly40, respectively, was placed with its exposed surface3aof the backing7comprising the male fastening elements4, onto the fibrous material32and rolled down in one cycle using a roll-down hard rubber roll of 5,000 g at a speed of 30.5 cm/min. The dimensions of the sample of the fibrous material32exceeded those of said piece of the fastening film system1or the assembly40, respectively, so that all of the exposed surface of such piece was contacting the sample of the fibrous material32. The resulting construction comprising the fastening film system1or the assembly40, respectively, and the fibrous material substrate32was clamped at one end and hung vertically for 15 minutes after which a 100 g weight was attached to the loose bottom end of the resulting construction, generating a shear load at an 180° angle. The time that it took in minutes for the weight to drop at room temperature was recorded as a measure of the hang shear adhesion.

Static Friction

The static friction was measured according to DIN53375. A piece of the fastening film system1or the assembly40, respectively, was mounted onto a sledge with the surface3aof the backing7being exposed, and placed against a sample of the fibrous material32to be tested. The sledge was then pulled with a constant speed of 10 cm/min into a direction within the interfacial area (i.e. normal to the surface vector of the exposed surface3aof the backing7) between the fibrous material32and the exposed surface3aof the backing7of the fastening film system1.

EXAMPLES

A portion of a mushroom-type hook web which is commercially available under the trade designation 3M Microreplicated Hook CS-600 from 3M Company, St Paul, Minn., USA, was provided. The portion had the dimension of 40 mm in CD and of 50 mm in MD. The thickness of the hook web including the height of the hook male fastening elements4was 396 μm. The average height of the hook male fastening elements4was about 310 μm. The hook male fastening elements4were integral with the backing7of the hook web, and they were distributed essentially homogenously across the surface area of the hook web at a density of 1,626 hooks/inch2. The single hook male fastening elements had a stem4awith a diameter of about 250 μm and an enlarged, oval-shaped portion4bat the end of the stems opposite to the backing7of the hook web.

Circular through-holes2were inserted into the portion of the hook by punching whereby the through-holes2extended normal to and throughout the backing7of the hook web. The circular through-holes2each had a diameter of 10 mm.

The hook web thus prepared was then laminated onto a PP film substrate5bearing a polystyrene-polyisoprene block-copolymer pressure-sensitive adhesive layer with a thickness of about 35 μm.

The distance between the through-holes2was approximately between 1 and 15 mm and was varied to give different ratios of the exposed adhesive area (=surface area of through-holes2) over the surface area of backing7(including the surface area of the through-holes2) of 0.2, 0.4 and 0.6. For comparative purposes, the ratios of the exposed adhesive area over the surface area of the backing7of 0 (=hook web comprising no holes) and 1 (no hook web, only exposed adhesive layer) were tested as well.

A sample of a 100% cotton fabric (=fibrous material32) having dimensions exceeding the dimensions of the piece of assembly40obtained above, was cut from a piece of plain commercial women's undergarment The sample was washed once and had a total weight of 195 g/m2after washing.

Another sample of a nylon/Elasthan™ fabric (96% nylon, 4% Elasthan) having dimensions exceeding the dimensions of the piece of the assembly40obtained above, was cut from a piece of a plain commercial women's undergarment. The sample was washed once and had a total weight of 170 g/m2after washing.

The samples of the cotton fabric and the nylon/Elasthan fabric were rolled down on the portion of the assembly40and, for purposes of comparison, to the hook web and the pure adhesive layer6, respectively, as described above using a roll down weight of 5 kg.

The results are summarized in Table 1 below and shown graphically inFIG. 4.

It can be seen from table 1 and the graphical representation inFIG. 4that the assembly40obtained in Example 1 exhibits a well-balanced ratio of an adhesive and mechanical bonding mechanism with respect to both the cotton fabric and the nylon/Elasthan fabric over a broad range of the ratio of the exposed surface area of through-holes2(=adhesive area) over the surface area of the backing7(=area of the backing7including the surface area of through-holes2). Such ratio preferably is between 0.5 and 0.7. The assembly40of Example 1 is therefore suitable for use with different fibrous materials32having different total weights of 170 and 195 g/m2, respectively.

Example 1 was repeated for a ratio of the surface area of through-holes2over the surface area of the backing7of 0.2 with the difference that the through-holes2had a diameter of 5 mm. The distance of the through-holes2was approx. 5 mm. All other parameters and conditions were identical to those of Example 1.

The results are shown in Table 2.

Example 1 was repeated with the difference that another hook web which is commercially available under the trade designation CS-1010 from 3M Company, St. Paul, Minn., USA, was used. The thickness of the hook web including the height of the hook male fastening elements4was 575 μm. The average height of the hook male fastening elements4was about 446 μm. The hooks4were integral with the backing7of the hook web, and they were distributed essentially homogenously across the surface area of the hook web at a density of 490 hooks/inch2. The single hook male fastening element4had a stem4awith a diameter in CD of about 238 μm and a diameter in MD of about 360 μm and an enlarged, anchor-shaped portion4bhaving two protrusions emanating from the stem and bending downwards, at the end of the stems opposite to the backing7of the hook web. All other parameters and conditions were identical to those used in Example 1.

The results are summarized in table 3 and plotted inFIG. 5.

It can be seen from table 3 and the graphical representation inFIG. 5that the assembly40obtained in Example 3 exhibits a well-balanced ratio of an adhesive bonding mechanism with respect to both the cotton fabric and the nylon/Elasthan fabric over a broad range of the ratio of the surface area of through-holes2(=exposed adhesive area) over the surface area of the backing7(=area of backing7including the surface area of through-holes2). Such ratio preferably is between 0.4 and 0.9. The assembly40of Example 3 is therefore suitable for use with different fibrous materials32having different total weights of 170 and 195 g/m2, respectively.

Example 1 was repeated using a stem web instead of the hook web. The stem web which was made according to the teaching of Example 1 of U.S. Pat. No. 4,959,268 comprises single stem male fastening elements4having a stem4awith a diameter of about 215 μm but no enlarged portion at the end of the stems. The thickness of the stem web including the height of the stems4awas about 520 μm. The average height of the stems was about 430 μm. The stems4awere integral with the backing7of the stem web, and they were distributed essentially homogenously across the surface of the stem web at a density of 1,600 stems/inch2.

All other parameters and conditions were identical to those used in Example 1.

The results are summarized in Table 4.

TABLE 4Ratio of thesurface area ofAverage 90°Average hangStaticthrough-holespeel adhesionshear adhesionfriction2 over the[N/40 mm][min/40 mm × 50 mm][mm]surface areaNylon/Nylon/Nylon/of backing 7CottonElasthanCottonElasthanElasthan0000*0.20.5>0.3>1,200n.m. **0.41.0>0.8>1,200n.m. *** the stem web mounted onto the sledge used in DIN 53375 for measuring the static friction was pushed at its front side (i.e. opposite to the side onto which the force was acting) so deep into the fibrous material 32 that the opposite side lost contact to the fibrous material 32 so that meaningful values could not be measured; the sledge did not move initially at all and was then pulled away from any contact with the fibrous material 32 when continuing to move the sledge along with a constant velocity of cm/min** not measured

It can be seen from table 4 that the unmodified stem web backing7comprising no through-holes2did not exhibit a 90° peel adhesion or a hang shear adhesion with respect to a fibrous cotton or nylon/Elasthan material32, respectively. The stem-type male fastening elements4mechanically interact, however, with the fibrous material32as can be seen from the static friction measurements. When introducing through-holes2into the stem web backing7an adhesive bonding mechanism is present as can be seen from the 90° peel adhesion and hang shear adhesion values for a ratio of the surface area of through-holes2(=exposed adhesive surface area) over the surface area of the backing7(=area of the backing7including the surface area of through-holes2) of 0.2 and 0.4.

Comparative Examples 1-3

Sanitary napkins commercially available from Procter & Gamble under the trade designation “Always Ultra-normal”, from Hartmann under the trade designation “Ria Pantiliners light, air-active” and from Schlecker under the trade designation “AS Classic” were obtained. The garment side of these sanitary napkins comprised an adhesive layer, either arranged in a single strip or in two narrower strips separated by an uncoated area.

The cotton sample and the nylon/Elasthan sample described in Example 1 were attached to such commercially available sanitary napkins using a roll down weight of 5 kg.

The 90° peel adhesion and the hang shear adhesion were measured as indicated in the test method section above.

The results are summarized in table 5 below.

Example 5 and Comparative Example 4

Example 1 was repeated for a ratio of the area of through-holes2(=exposed adhesive surface) over the surface area of the backing7of 0.2, 0.4 or 0.6 using through-holes2with a diameter of 10 mm. In a comparative example, the same ratios of 0.2, 0.4 and 0.6 were obtained using a sequence of a first strip of a hook web with no through-holes, a strip with no hook web, i.e. an 8 mm wide strip of the exposed adhesive surface and a second strip of a hook web. The width of theses strips was as follows:

TABLE 6Ratio of the surfacearea of through-holes2 over the surfaceWidth [mm]area of backing 71sthook stripadhesive strip2ndhook strip0.2168160.41216120.68248

The results of the measurements are shown in Table 7 below.

It can be seen from table 7 that the assemblies40of Comparative Example 4 comprising strip-shaped exposed adhesive areas which are not fully encompassed by the backing7, have distinctly higher average 90° peel adhesion in comparison to the assembly40of the invention comprising through-holes2with a diameter of 10 mm. The adhesive and mechanical bonding mechanism of an assembly40of the invention having a ratio of the surface area of through-holes2(=exposed adhesive surface) over the surface area of the backing7(=area of backing7including the surface area of the through-holes2) of 0.6, is characterized by an advantageous 90° peel adhesion value to both a cotton based surface and to a nylon based surface which is highly preferable. Such an optimised performance cannot be obtained with the strip-shaped adhesive and mechanical bonding elements.