Patent Description:
Disposable absorbent articles are used to receive and contain bodily wastes (e.g., bowel movements, urine, menses). Some example absorbent articles are diapers, pants, adult incontinence products, sanitary napkins, tampons, panty liners, and absorbent pads. These absorbent articles sometimes receive viscous liquid bodily waste, such as low viscosity feces, for example. In some configurations, the absorbent articles may have an apertured topsheet and a porous sublayer disposed under the topsheet. The porous sublayer may be referred to as an acquisition layer or material. Viscous liquid bodily waste deposited on the apertured topsheet may, to some extent, penetrate the topsheet, primarily through the apertures in the topsheet if the apertures are of a sufficient size, and be partially acquired and stored in the porous acquisition material away from the wearer's skin. Current absorbent articles, due to current acquisition materials, however, typically acquire and store much less than the average amount of low viscosity feces or liquid bodily waste deposited in them by infants, babies, children, and/or adult wearers (together "wearer(s)"). This sometimes leads to leakage of the low viscosity feces or waste from the absorbent articles (e.g., up the back or over the cuffs), undesirable amounts of the low viscosity feces or waste left on the wearer's skin, and/or large amounts of low viscosity feces or waste remaining on the topsheet of the absorbent articles. Accordingly, it would be desirable to produce absorbent articles having acquisition materials capable of acquiring and storing most, if not all, of the low viscosity feces or waste deposited in an absorbent article by a wearer.

<CIT> is concerned with laminate webs having a nonwoven web in facing relationship with a polymer film, which may be used as topsheet in absorbent article. The laminate web has a first side comprising the polymer film and a plurality of discrete tufts including fibers integral with and extending from the nonwoven web. At least part of the distal portion of each of the tufts is covered by a cap of the polymeric film. The cap has a opening including a location of rupture in the polymer film above which the tuft extends.

<CIT> relates to a sanitary napkin with a curved, body-conforming configuration. The sanitary napkin has a curved longitudinal profile in which the ends of the sanitary napkin are displaced upward. The absorbent core may comprise a laminate of superabsorbent material positioned between two layers or webs of modified cross-linked cellulosic fibers. The sanitary napkin further comprises a tufted bundle of capillary channel fibers that are positioned generally on top of the absorbent core.

<CIT> discloses an absorbent article comprising a waste management element with an acceptance element and a storage element. The storage element comprises a three-dimensional web with arcuate portions intermittent with bondable locations forming a lofted open structure.

The present invention is directed to an absorbent article comprising a liquid permeable topsheet, a liquid impermeable backsheet, an absorbent core disposed at least partially intermediate the topsheet and the backsheet, and an acquisition material disposed at least partially intermediate the topsheet and the absorbent core. The acquisition material has a caliper in the range of about <NUM> to about <NUM> mmaccording to the Caliper Test herein. The acquisition material has an Air Permeability in the range of about <NUM>,<NUM><NUM>/m<NUM>/s to about <NUM>,<NUM><NUM>/m<NUM>/s, according to the Air Permeability Test herein. The acquisition material comprises a first surface, a second surface, and three-dimensional features extending outwardly from the first surface. The acquisition material comprises two or more layers. The first layer and the second layer comprise the three-dimensional features, and wherein tips of the three-dimensional features of the first layer are joined with tips of the three-dimensional features of the second layer.

The above-mentioned and other features and advantages of the present disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following description of example forms of the disclosure taken in conjunction with the accompanying drawings, wherein:.

Various non-limiting forms of the present disclosure will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the Absorbent Articles With Improved Low Viscosity Waste Acquisition disclosed herein. One or more examples of these non-limiting forms are illustrated in the accompanying drawings. Those of ordinary skill in the art will understand that the Absorbent Articles With Improved Low Viscosity Waste Acquisition described herein and illustrated in the accompanying drawings are non-limiting example forms and that the scope of the various non-limiting forms of the present disclosure are defined solely by the claims. The features illustrated or described in connection with one non-limiting form may be combined with the features of other non-limiting forms. Such modifications and variations are intended to be included within the scope of the present disclosure.

First, example absorbent articles will be discussed, followed by a discussion of the acquisition materials of the present disclosure.

An example absorbent article <NUM> according to the present disclosure, shown in the form of a taped diaper, is represented in <FIG>. <FIG> is a plan view of the example absorbent article <NUM>, garment-facing surface <NUM> facing the viewer in a flat, laid-out state (i.e., no elastic contraction). <FIG> is a plan view of the example absorbent article <NUM> of <FIG>, wearer-facing surface <NUM> facing the viewer in a flat, laid-out state. <FIG> is a front perspective view of the absorbent article <NUM> of <FIG> and <FIG> in a fastened configuration. The absorbent article <NUM> of <FIG> is shown for illustration purposes only as the present disclosure may be used for making a wide variety of diapers, including adult incontinence products, pants, or other absorbent articles, such as sanitary napkins and absorbent pads, for example.

The absorbent article <NUM> may comprise a front waist region <NUM>, a crotch region <NUM>, and a back waist region <NUM>. The crotch region <NUM> may extend intermediate the front waist region <NUM> and the back waist region <NUM>. The front wait region <NUM>, the crotch region <NUM>, and the back waist region <NUM> may each be <NUM>/<NUM> of the length of the absorbent article <NUM>. The absorbent article <NUM> may comprise a front end edge <NUM>, a back end edge <NUM> opposite to the front end edge <NUM>, and longitudinally extending, transversely opposed side edges <NUM> and <NUM> defined by the chassis <NUM>.

The absorbent article <NUM> may comprise a liquid permeable topsheet <NUM>, a liquid impermeable backsheet <NUM>, and an absorbent core <NUM> positioned at least partially intermediate the topsheet <NUM> and the backsheet <NUM>. The absorbent article <NUM> may also comprise one or more pairs of barrier leg cuffs <NUM> with or without elastics <NUM>, one or more pairs of leg elastics <NUM>, one or more elastic waistbands <NUM>, and/or one or more acquisition materials <NUM>. The acquisition material or materials <NUM> may be positioned intermediate the topsheet <NUM> and the absorbent core <NUM>. An outer cover material <NUM>, such as a nonwoven material, may cover a garment-facing side of the backsheet <NUM>. The absorbent article <NUM> may comprise back ears <NUM> in the back waist region <NUM>. The back ears <NUM> may comprise fasteners <NUM> and may extend from the back waist region <NUM> of the absorbent article <NUM> and attach (using the fasteners <NUM>) to the landing zone area or landing zone material <NUM> on a garment-facing portion of the front waist region <NUM> of the absorbent article <NUM>. The absorbent article <NUM> may also have front ears <NUM> in the front waist region <NUM>. The absorbent article <NUM> may have a central lateral (or transverse) axis <NUM> and a central longitudinal axis <NUM>. The central lateral axis <NUM> extends perpendicular to the central longitudinal axis <NUM>.

In other instances, the absorbent article may be in the form of a pant having permanent or refastenable side seams. Suitable refastenable seams are disclosed in <CIT> and <CIT>. Referring to <FIG>, an example absorbent article <NUM> in the form of a pant is illustrated. <FIG> is a front perspective view of the absorbent article <NUM>. <FIG> is a rear perspective view of the absorbent article <NUM>. <FIG> is a plan view of the absorbent article <NUM>, laid flat, with the garment-facing surface facing the viewer. Elements of <FIG> having the same reference number as described above with respect to <FIG> may be the same element (e.g., absorbent core <NUM>). <FIG> is an example cross-sectional view of the absorbent article taken about line <NUM>-<NUM> of <FIG>. <FIG> is an example cross-sectional view of the absorbent article taken about line <NUM>-<NUM> of <FIG>. <FIG> and <FIG> illustrate example forms of front and back belts <NUM>, <NUM>. The absorbent article <NUM> may have a front waist region <NUM>, a crotch region <NUM>, and a back waist region <NUM>. Each of the regions <NUM>, <NUM>, and <NUM> may be <NUM>/<NUM> of the length of the absorbent article <NUM>. The absorbent article <NUM> may have a chassis <NUM> (sometimes referred to as a central chassis or central panel) comprising a topsheet <NUM>, a backsheet <NUM>, and an absorbent core <NUM> disposed at least partially intermediate the topsheet <NUM> and the backsheet <NUM>, and an optional acquisition material <NUM>, similar to that as described above with respect to <FIG>. The absorbent article <NUM> may comprise a front belt <NUM> in the front waist region <NUM> and a back belt <NUM> in the back waist region <NUM>. The chassis <NUM> may be joined to a wearer-facing surface <NUM> of the front and back belts <NUM>, <NUM> or to a garment-facing surface <NUM> of the belts <NUM>, <NUM>. Side edges <NUM> and <NUM> of the front belt <NUM> may be joined to side edges <NUM> and <NUM>, respectively, of the back belt <NUM> to form two side seams <NUM>. The side seams <NUM> may be any suitable seams known to those of skill in the art, such as butt seams or overlap seams, for example. When the side seams <NUM> are permanently formed or refastenably closed, the absorbent article <NUM> in the form of a pant has two leg openings <NUM> and a waist opening circumference <NUM>. The side seams <NUM> may be permanently joined using adhesives or bonds, for example, or may be refastenably closed using hook and loop fasteners, for example.

Referring to <FIG> and <FIG>, the front and back belts <NUM> and <NUM> may comprise front and back inner belt layers <NUM> and <NUM> and front and back outer belt layers <NUM> and <NUM> having an elastomeric material (e.g., strands <NUM> or a film (which may be apertured)) disposed at least partially therebetween. The elastic elements <NUM> or the film may be relaxed (including being cut) to reduce elastic strain over the absorbent core <NUM> or, may alternatively, run continuously across the absorbent core <NUM>. The elastics elements <NUM> may have uniform or variable spacing therebetween in any portion of the belts. The elastic elements <NUM> may also be pre-strained the same amount or different amounts. The front and/or back belts <NUM> and <NUM> may have one or more elastic element free zones <NUM> where the chassis <NUM> overlaps the belts <NUM>, <NUM>. In other instances, at least some of the elastic elements <NUM> may extend continuously across the chassis <NUM>.

The front and back inner belt layers <NUM>, <NUM> and the front and back outer belt layers <NUM>, <NUM> may be joined using adhesives, heat bonds, pressure bonds or thermoplastic bonds. Various suitable belt layer configurations can be found in <CIT>.

Front and back belt end edges <NUM> and <NUM> may extend longitudinally beyond the front and back chassis end edges <NUM> and <NUM> (as shown in <FIG>) or they may be co-terminus. The front and back belt side edges <NUM>, <NUM>, <NUM>, and <NUM> may extend laterally beyond the chassis side edges <NUM> and <NUM>. The front and back belts <NUM> and <NUM> may be continuous (i.e., having at least one layer that is continuous) from belt side edge to belt side edge (e.g., the transverse distances from <NUM> to <NUM> and from <NUM> to <NUM>). Alternatively, the front and back belts <NUM> and <NUM> may be discontinuous from belt side edge to belt side edge (e.g., the transverse distances from <NUM> to <NUM> and <NUM> to <NUM>), such that they are discrete.

As disclosed in <CIT>, the longitudinal length (along the central longitudinal axis <NUM>) of the back belt <NUM> may be greater than the longitudinal length of the front belt <NUM>, and this may be particularly useful for increased buttocks coverage when the back belt <NUM> has a greater longitudinal length versus the front belt <NUM> adjacent to or immediately adjacent to the side seams <NUM>.

The front outer belt layer <NUM> and the back outer belt layer <NUM> may be separated from each other, such that the layers are discrete or, alternatively, these layers may be continuous, such that a layer runs continuously from the front belt end edge <NUM> to the back belt end edge <NUM>. This may also be true for the front and back inner belt layers <NUM> and <NUM> - that is, they may also be longitudinally discrete or continuous. Further, the front and back outer belt layers <NUM> and <NUM> may be longitudinally continuous while the front and back inner belt layers <NUM> and <NUM> are longitudinally discrete, such that a gap is formed between them - a gap between the front and back inner and outer belt layers <NUM>, <NUM>, <NUM>, and <NUM> is shown in <FIG> and a gap between the front and back inner belt layers <NUM> and <NUM> is shown in <FIG>.

The front and back belts <NUM> and <NUM> may include slits, holes, and/or perforations providing increased breathability, softness, and a garment-like texture. Underwear-like appearance can be enhanced by substantially aligning the waist and leg edges at the side seams <NUM> (see <FIG> and <FIG>).

The front and back belts <NUM> and <NUM> may comprise graphics (see e.g., <NUM> of <FIG>). The graphics may extend substantially around the entire circumference of the absorbent article <NUM> and may be disposed across side seams <NUM> and/or across proximal front and back belt seams <NUM> and <NUM>; or, alternatively, adjacent to the seams <NUM>, <NUM>, and <NUM> in the manner described in <CIT>, <CIT> to create a more underwear-like article. The graphics may also be discontinuous.

Alternatively, instead of attaching belts <NUM> and <NUM> to the chassis <NUM> to form a pant, discrete side panels may be attached to side edges of the chassis <NUM> and <NUM>.

The topsheet <NUM> is the part of the absorbent article <NUM> that is in contact with the wearer's skin. The topsheet <NUM> may be joined to portions of the backsheet <NUM>, the absorbent core <NUM>, the barrier leg cuffs <NUM>, and/or any other layers as is known to those of ordinary skill in the art. The topsheet <NUM> may be compliant, soft-feeling, and non-irritating to the wearer's skin. Further, at least a portion of, or all of, the topsheet may be liquid permeable, permitting liquid bodily wastes to readily penetrate through its thickness. A suitable topsheet may be manufactured from a wide range of materials, such as porous foams, reticulated foams, apertured plastic films, woven materials, nonwoven materials, woven or nonwoven materials of natural fibers (e.g., wood or cotton fibers), synthetic fibers or filaments (e.g., polyester or polypropylene or bicomponent PE/PP fibers or mixtures thereof), or a combination of natural and synthetic fibers. The topsheet may have one or more layers. The topsheet may be apertured (<FIG>, element <NUM>), may have any suitable three-dimensional features, and/or may have a plurality of embossments (e.g., a bond pattern). The topsheet may be apertured by overbonding a material and then rupturing the overbonds through ring rolling, such as disclosed in <CIT> and disclosed in <CIT> Any portion of the topsheet may be coated with a skin care composition, an antibacterial agent, a surfactant, and/or other beneficial agents. The topsheet may be hydrophilic or hydrophobic or may have hydrophilic and/or hydrophobic portions or layers. If the topsheet is hydrophobic, typically apertures will be present so that bodily wastes may pass through the top sheet.

The backsheet <NUM> is generally that portion of the absorbent article <NUM> positioned proximate to the garment-facing surface of the absorbent core <NUM>. The backsheet <NUM> may be joined to portions of the topsheet <NUM>, the outer cover material <NUM>, the absorbent core <NUM>, and/or any other layers of the absorbent article by any attachment methods known to those of skill in the art. The backsheet <NUM> prevents, or at least inhibits, the bodily wastes absorbed and contained in the absorbent core <NUM> from soiling articles such as bedsheets, undergarments, and/or clothing. The backsheet is typically liquid impermeable, or at least substantially liquid impermeable. The backsheet may, for example, be or comprise a thin plastic film, such as a thermoplastic film having a thickness of about <NUM> to about <NUM>. Other suitable backsheet materials may include breathable materials which permit vapors to escape from the absorbent article, while still preventing, or at least inhibiting, bodily wastes from passing through the backsheet.

The outer cover nonwoven material (sometimes referred to as a backsheet nonwoven) <NUM> may comprise one or more nonwoven materials joined to the backsheet <NUM> and that covers the backsheet <NUM>. The outer cover nonwoven material <NUM> forms at least a portion of the garment-facing surface <NUM> of the absorbent article <NUM> and effectively "covers" the backsheet <NUM> so that film is not present on the garment-facing surface <NUM>. The outer cover nonwoven material <NUM> may comprise a bond pattern, apertures, and/or three-dimensional features.

As used herein, the term "absorbent core" <NUM> refers to the component of the absorbent article <NUM> having the most absorbent capacity and that comprises an absorbent material. Referring to <FIG>, in some instances, absorbent material <NUM> may be positioned within a core bag or a core wrap <NUM>. The absorbent material may be profiled or not profiled, depending on the specific absorbent article. The absorbent core <NUM> may comprise, consist essentially of, or consist of, a core wrap, absorbent material <NUM>, and glue enclosed within the core wrap. The absorbent material may comprise superabsorbent polymers, a mixture of superabsorbent polymers and air felt, only air felt, and/or a high internal phase emulsion foam. In some instances, the absorbent material may comprise at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, or up to <NUM>% superabsorbent polymers, by weight of the absorbent material. In such instances, the absorbent material may be free of air felt, or at least mostly free of air felt. The absorbent core periphery, which may be the periphery of the core wrap, may define any suitable shape, such as rectangular "T," "Y," "hour-glass," or "dog-bone" shaped, for example. An absorbent core periphery having a generally "dog bone" or "hour-glass" shape may taper along its width towards the crotch region <NUM> of the absorbent article <NUM>.

Referring to <FIG>, the absorbent core <NUM> may have areas having little or no absorbent material <NUM>, where a wearer-facing surface of the core bag <NUM> may be joined to a garment-facing surface of the core bag <NUM>. These areas having little or no absorbent material and may be referred to as "channels" <NUM>. These channels can embody any suitable shapes and any suitable number of channels may be provided. In other instances, the absorbent core may be embossed to create the impression of channels. The absorbent core in <FIG> is merely an example absorbent core. Many other absorbent cores with or without channels are also within the scope of the present disclosure.

Referring to <FIG> and <FIG>, for example, the absorbent article <NUM> may comprise one or more pairs of barrier leg cuffs <NUM> and one or more pairs of leg elastics <NUM>. The barrier leg cuffs <NUM> may be positioned laterally inboard of leg elastics <NUM>. Each barrier leg cuff <NUM> may be formed by a piece of material which is bonded to the absorbent article <NUM> so it can extend upwards from a wearer-facing surface <NUM> of the absorbent article <NUM> and provide improved containment of body wastes approximately at the junction of the torso and legs of the wearer. The barrier leg cuffs <NUM> are delimited by a proximal edge joined directly or indirectly to the topsheet and/or the backsheet and a free terminal edge, which is intended to contact and form a seal with the wearer's skin. The barrier leg cuffs <NUM> may extend at least partially between the front end edge <NUM> and the back end edge <NUM> of the absorbent article <NUM> on opposite sides of the central longitudinal axis <NUM> and may be at least present in the crotch region <NUM>. The barrier leg cuffs <NUM> may each comprise one or more elastics <NUM> (e.g., elastic strands or strips) near or at the free terminal edge. These elastics <NUM> cause the barrier leg cuffs <NUM> to help form a seal around the legs and torso of a wearer. The leg elastics <NUM> extend at least partially between the front end edge <NUM> and the back end edge <NUM>. The leg elastics <NUM> essentially cause portions of the absorbent article <NUM> proximate to the chassis side edges <NUM>, <NUM> to help form a seal around the legs of the wearer. The leg elastics <NUM> may extend at least within the crotch region <NUM>.

Referring to <FIG> and <FIG>, the absorbent article <NUM> may comprise one or more elastic waistbands <NUM>. The elastic waistbands <NUM> may be positioned on the garment-facing surface <NUM> or the wearer-facing surface <NUM>. As an example, a first elastic waistband <NUM> may be present in the front waist region <NUM> near the front belt end edge <NUM> and a second elastic waistband <NUM> may be present in the back waist region <NUM> near the back end edge <NUM>. The elastic waistbands <NUM> may aid in sealing the absorbent article <NUM> around a waist of a wearer and at least inhibiting bodily wastes from escaping the absorbent article <NUM> through the waist opening circumference. In some instances, an elastic waistband may fully surround the waist opening circumference of an absorbent article.

Referring to <FIG> and <FIG>, the absorbent article <NUM> may have a landing zone area <NUM> that is formed in a portion of the garment-facing surface <NUM> of the outer cover material <NUM>. The landing zone area <NUM> may be in the back waist region <NUM> if the absorbent article <NUM> fastens from front to back or may be in the front waist region <NUM> if the absorbent article <NUM> fastens back to front. In some instances, the landing zone <NUM> may be or may comprise one or more discrete nonwoven materials that are attached to a portion of the outer cover material <NUM> in the front waist region <NUM> or the back waist region <NUM> depending upon whether the absorbent article fastens in the front or the back. In essence, the landing zone <NUM> is configured to receive the fasteners <NUM> and may comprise, for example, a plurality of loops configured to be engaged with, a plurality of hooks on the fasteners <NUM>, or vice versa.

Referring to <FIG>, the absorbent articles <NUM> of the present disclosure may comprise graphics <NUM> and/or wetness indicators <NUM> that are visible from the garment-facing surface <NUM>. The graphics <NUM> may be printed on the landing zone <NUM>, the backsheet <NUM>, and/or at other locations. The wetness indicators <NUM> are typically applied to the absorbent core facing side of the backsheet <NUM>, so that they can be contacted by bodily wastes within the absorbent core <NUM>. In some instances, the wetness indicators <NUM> may form portions of the graphics <NUM>. For example, a wetness indicator may appear or disappear and create/remove a character within some graphics. In other instances, the wetness indicators <NUM> may coordinate (e.g., same design, same pattern, same color) or not coordinate with the graphics <NUM>.

Referring to <FIG> and <FIG>, as referenced above, the absorbent article <NUM> may have front and/or back ears <NUM>, <NUM> in a taped diaper context. Only one set of ears may be required in most taped diapers. The single set of ears may comprise fasteners <NUM> configured to engage the landing zone or landing zone area <NUM>. If two sets of ears are provided, in most instances, only one set of the ears may have fasteners <NUM>, with the other set being free of fasteners. The ears, or portions thereof, may be elastic or may have elastic panels. In an example, an elastic film or elastic strands may be positioned intermediate a first nonwoven material and a second nonwoven material. The elastic film may or may not be apertured. The ears may be shaped. The ears may be integral (e.g., extension of the outer cover material <NUM>, the backsheet <NUM>, and/or the topsheet <NUM>) or may be discrete components attached to a chassis <NUM> of the absorbent article on a wearer-facing surface <NUM>, on the garment-facing surface <NUM>, or intermediate the two surfaces <NUM>, <NUM>.

Referring again to <FIG>, the absorbent articles of the present disclosure may comprise a sensor system <NUM> for monitoring changes within the absorbent article <NUM>. The sensor system <NUM> may be discrete from or integral with the absorbent article <NUM>. The absorbent article <NUM> may comprise sensors that can sense various aspects of the absorbent article <NUM> associated with insults of bodily wastes (e.g., the sensor system <NUM> may sense variations in temperature, humidity, presence of ammonia or urea, various vapor components of the bodily wastes (urine and feces), changes in moisture vapor transmission through the absorbent articles garment-facing layer, changes in translucence of the garment-facing layer, and/or color changes through the garment-facing layer). Additionally, the sensor system <NUM> may sense components of urine, such as ammonia or urea and/or byproducts resulting from reactions of these components with the absorbent article <NUM>. The sensor system <NUM> may sense byproducts that are produced when urine mixes with other components of the absorbent article <NUM> (e.g., adhesives, agm). The components or byproducts being sensed may be present as vapors that may pass through the garment-facing layer. It may also be desirable to place reactants in the absorbent article that change state (e.g. color, temperature) or create a measurable byproduct when mixed with urine or BM. The sensor system <NUM> may also sense changes in pH, pressure, odor, the presence of gas, blood, a chemical marker or a biological marker or combinations thereof. The sensor system <NUM> may have a component on or proximate to the absorbent article that transmits a signal to a receiver more distal from the absorbent article, such as an iPhone, for example. The receiver may output a result to communicate to the caregiver a condition of the absorbent article <NUM>. In other instances, a receiver may not be provided, but instead the condition of the absorbent article <NUM> may be visually or audibly apparent from the sensor on the absorbent article.

The absorbent articles of the present disclosure may be placed into packages. The packages may comprise polymeric films and/or other materials. Graphics and/or indicia relating to properties of the absorbent articles may be formed on, printed on, positioned on, and/or placed on outer portions of the packages. Each package may comprise a plurality of absorbent articles. The absorbent articles may be packed under compression so as to reduce the size of the packages, while still providing an adequate number of absorbent articles per package. By packaging the absorbent articles under compression, caregivers can easily handle and store the packages, while also providing distribution savings to manufacturers owing to the size of the packages.

Referring to <FIG>, an absorbent article of the present disclosure may be a sanitary napkin <NUM>. The sanitary napkin <NUM> may comprise a liquid permeable topsheet <NUM>, a liquid impermeable, or substantially liquid impermeable, backsheet <NUM>, and an absorbent core <NUM>. The liquid impermeable backsheet <NUM> may or may not be vapor permeable. The absorbent core <NUM> may have any or all of the features described herein with respect to the absorbent core <NUM> and, in some forms, may have a secondary topsheet <NUM> (STS) instead of the acquisition materials disclosed above. The STS <NUM> may comprise one or more channels, as described above (including the embossed version). In some forms, channels in the STS <NUM> may be aligned with channels in the absorbent core <NUM>. The sanitary napkin <NUM> may also comprise wings <NUM> extending outwardly with respect to a longitudinal axis <NUM> of the sanitary napkin <NUM>. The sanitary napkin <NUM> may also comprise a lateral axis <NUM>. The wings <NUM> may be joined to the topsheet <NUM>, the backsheet <NUM>, and/or the absorbent core <NUM>. The sanitary napkin <NUM> may also comprise a front edge <NUM>, a back edge <NUM> longitudinally opposing the front edge <NUM>, a first side edge <NUM>, and a second side edge <NUM> longitudinally opposing the first side edge <NUM>. The longitudinal axis <NUM> may extend from a midpoint of the front edge <NUM> to a midpoint of the back edge <NUM>. The lateral axis <NUM> may extend from a midpoint of the first side edge <NUM> to a midpoint of the second side edge <NUM>. The sanitary napkin <NUM> may also be provided with additional features commonly found in sanitary napkins as is known in the art.

Next, the acquisition materials of the present disclosure will be discussed. Referring to <FIG>, <FIG>, <FIG>, and <FIG>, one or more acquisition materials <NUM> may be present at least partially intermediate the topsheet <NUM> and the absorbent core <NUM>. The acquisition materials <NUM> may comprise one or more hydrophilic nonwoven materials that provide wicking of bodily wastes. The acquisition materials <NUM> may also comprise one or more hydrophobic nonwoven materials or acquisition materials that have hydrophilic and hydrophobic portions or layers. These materials may dewater the topsheet <NUM> and quickly acquire and store low viscosity waste or feces. The acquisition materials <NUM> may comprise one or more nonwoven materials. The nonwoven acquisition materials may be resin bonded materials with about <NUM>% to about <NUM>%, or about <NUM>% fibers, by weight of the acquisition material, and about <NUM>% to about <NUM>%, or about <NUM>% latex binder, by weight of the acquisition material. The fibers may comprise carded fibers. Acquisition materials may also comprise other nonwoven materials, cellulosic materials, high-loft nonwoven materials, spunbond high-loft nonwoven materials, and/or foams, for example. The high-loft nonwoven materials may comprise polyolefins, polyesters, and/or polyurethanes, for example. Alternative structures may comprise large diameter filaments (e.g., <NUM>, <NUM>, or even <NUM>) randomly laid down and intersecting one another at bonding points. Typically, an acquisition material <NUM> may have a width and length that are smaller than the width and length of the topsheet <NUM>. The acquisition material may be a secondary topsheet in the feminine pad or sanitary napkin context. The acquisition material may have one or more channels as described above with reference to the absorbent core <NUM> (including the embossed version). The channels in the acquisition material may align or not align with any channels in the absorbent core <NUM>. In some instances, a cross-linked cellulosic layer may be positioned intermediate the acquisition material and the topsheet. In other instances, the acquisition material (whether one or more layers) may be positioned intermediate the topsheet and the absorbent core.

The acquisition materials (whether one or more layers) of the present disclosure have a caliper in the range of about <NUM> to about <NUM>, about <NUM> to about <NUM>, or about <NUM> to about <NUM>, about <NUM> to about <NUM>, or about <NUM> to about <NUM>, specifically reciting all <NUM> increments within the specified ranges and all ranges formed therein or thereby. All caliper measurements are according to the Caliper Test herein.

The acquisition materials (whether one or more layers) of the present disclosure have an air permeability in the range of about <NUM>,<NUM>/m<NUM>/s to about <NUM>,<NUM>/m<NUM>/s, about <NUM>,<NUM>/m<NUM>/s to about <NUM>,<NUM>/m<NUM>/s, about <NUM>,<NUM>/m<NUM>/s to about <NUM>,<NUM>/m<NUM>/s, specifically reciting all <NUM>/m<NUM>/s increments within the specified ranges and all ranges formed therein or thereby. All air permeability measurements are according to the Air Permeability Test herein.

The acquisition materials (whether one or more layers) of the present disclosure may have a basis weight in the range of about <NUM> gsm to about <NUM> gsm, about <NUM> gsm to about <NUM> gsm, about <NUM> gsm to about <NUM> gsm, about <NUM> gsm to about <NUM> gsm, about <NUM> gsm to about <NUM> gsm, about <NUM> gsm to about <NUM> gsm, or about <NUM> gsm, specifically reciting all <NUM> gsm increments within the specified ranges and all ranges formed therein or thereby. All basis weight measurements are according to the Basis Weight Test herein.

The acquisition materials <NUM> of the present disclosure comprises multiple layers, such as two or three layers, for example. <FIG> is a schematic illustration of side view of a single layer acquisition material <NUM>. <FIG> is a schematic illustration of a side view of a two layer acquisition material <NUM>. The first layer are joined (e.g., bonds, adhesives) to the second layer. In instances, the first layer may only be joined to the second layer in certain areas and not joined in other areas. Alternatively, the first and second layers, or portions thereof, may be joined only by physical or geometric interactions, such as by being mechanically entangled or nested, for example. If more than one layer is provided in an acquisition material, each layer may be the same or different in fiber type, composition, basis weight, air permeability, dimensions, caliper, and/or density, for example. The acquisition materials may be rectangular or may be shaped (e.g., not rectangular, such as hourglass shaped).

The acquisition materials comprise three-dimensional features or may - not according to the claimed invention - be "activated" or "mechanically activated". Examples of tooling for activation or mechanical activation is illustrated in <FIG>, <FIG>, <FIG>, and <FIG>. An example of an activated nonwoven or mechanically activated nonwoven is illustrated in <FIG>. Any suitable physical process that increases the caliper and air permeability of the material may be classified in the context of activation or mechanical activation. This may lead to more storage space for low viscosity feces or waste and further improve acquisition through a topsheet, or other layer, and into the acquisition material. <FIG> are schematic illustrations of side views of acquisition materials. The acquisition material <NUM> may comprise a first surface <NUM>, a second surface <NUM>, and three-dimensional features <NUM> extending outwardly from the first surface <NUM> or the second surface <NUM>. The three-dimensional features <NUM> may extend toward the absorbent core or may extend toward the topsheet when placed in an absorbent article. In some instances, some three-dimensional features may extend toward the topsheet and other three-dimensional features may extend towards the absorbent core (see <FIG>). In such an instance, the three-dimensional features <NUM> may extend outwardly from the first surface <NUM> and extend outwardly from the second surface <NUM>. <FIG> illustrate two layer acquisition materials in a "nested" structure, but it will be understood that only one layer may be used while still retaining the same structure of the three-dimensional features <NUM>. Void spaces <NUM> are created in the acquisition materials <NUM> via the three-dimensional features <NUM>. These void spaces <NUM> aid in acquisition and storage of low viscosity feces or waste, thereby inhibiting blowouts and waste on skin. The first surface <NUM> or the second surface <NUM> of the acquisition materials <NUM> of <FIG> may face the topsheet of an absorbent article. Low viscosity feces or waste may enter the void spaces through the first layer or the second layer owing to the open porosity and high air permeability of the layers.

At least some of, a majority of, or all of the three-dimensional features may have an area in the range of about <NUM><NUM> to about <NUM><NUM>, about <NUM><NUM> to about <NUM><NUM>, about <NUM><NUM> to about <NUM><NUM>, or about <NUM><NUM> to about <NUM><NUM>, specifically reciting all <NUM><NUM> increments within the specified ranges and all ranges formed therein or thereby. At least some of, a majority of, or all of the three-dimensional features may have a largest dimension in the range of about <NUM> to about <NUM>, about <NUM> to about <NUM>, or about <NUM> to about <NUM>, specifically reciting all <NUM> increments within the specified ranges and all ranges formed therein or thereby. The "largest dimension" means the longest measurable length through an X-Y plane at a base of a three-dimensional feature taken at its widest point or across its largest perimeter (whether the perimeter is continuous or discontinuous). The X-Y plane extends in the same direction as the first surface <NUM> and the second surface <NUM>. The three-dimensional features may have any suitable X-Y plane shape, such as hearts, circles, ovals, octagons, rectangles, elongate bars, or squares, for example. In some instances, all of the three-dimensional elements may be the same shape (accounting for manufacturing tolerances) in an acquisition material. In other instances, more than one shape of three-dimensional features may be provided in an acquisition material.

<FIG> is a schematic illustration of a side view of a two layer acquisition material <NUM> having a first layer <NUM> and a second layer <NUM>. The first layer <NUM> comprises three-dimensional features <NUM> and the second layer comprises three-dimensional features <NUM>. Tips of the three-dimensional features <NUM> are joined (e.g., bonded or glued) <NUM> to tips of the three-dimensional features <NUM> to create large void spaces <NUM> in the acquisition material <NUM>. These large void spaces <NUM> may aid in acquisition and storage of low viscosity feces or waste, thereby inhibiting blowouts or waste on skin. Void spaces may also be created in the three-dimensional features <NUM>, <NUM>. Low viscosity feces or waste may enter the void spaces through the first layer or the second layer owing to their open porosity and high air permeability.

<FIG> is a schematic illustration of a side view of a two layer acquisition material <NUM> having a first layer <NUM> and a second layer <NUM>. The first layer <NUM> comprises three-dimensional features <NUM> and the second layer <NUM> may be generally planar. Tips of the three-dimensional features <NUM> of the first layer <NUM> may be joined (e.g., bonded or glued) <NUM> to the planer second layer <NUM> to create large void spaces <NUM> in the acquisition material <NUM>. In other instances, the tips may not be joined to the second layer <NUM>. These void spaces <NUM> may aid in acquisition and storage of low viscosity feces or waste, thereby inhibiting blowouts and waste on skin. Void spaces may also be created in the three-dimensional features <NUM>. The generally planar second layer <NUM> may face the topsheet or may face the absorbent core in an absorbent article. Low viscosity feces or waste may enter the void spaces through the first layer or the second layer owing to their open porosity and high air permeability.

As an example, the three-dimensional features discussed herein may be created via male female embossing and/or mechanical intermeshing. <FIG> illustrate example male embossing or mechanical intermeshing tooling that may be used with the female embossing or mechanical intermeshing tooling of <FIG> to create a pattern of three-dimensional features in an acquisition material. The male-female embossing or mechanical intermeshing may be used to create void spaces in and activate or mechanically activate an acquisition material. One or more layers may be embossed or mechanical intermeshed together (see <FIG>) or single layers may be embossed or mechanical intermeshed separately. If single layers are embossed or mechanical intermeshed separately, they may optionally be joined with other embossed or mechanical intermeshed single layers to create, for example, the structure illustrated in <FIG>. Also, if single layers are embossed or mechanical intermeshed separately, they may be joined with a generally planar layer to create the structure of <FIG>.

<FIG> is a perspective view of a plate comprising male embossing or mechanical intermeshing tooling. <FIG> is a top view of the plate comprising the male embossing or mechanical intermeshing tooling of <FIG> is detail view of <FIG>. A plurality of projections <NUM> may extend outwardly from a surface <NUM> of the male embossing or mechanical intermeshing tooling. The projections <NUM> may have the illustrated shape, a cylindrical shape, or other suitable shape. Although the male embossing or mechanical intermeshing tooling is illustrated on a plate, it will be understood that such tooling may also be provided on an outer surface of a cylindrical roll. <FIG> is a perspective view of a plate comprising female embossing or mechanical intermeshing tooling. <FIG> is a top view of the plate comprising the female embossing or mechanical intermeshing tooling of <FIG> is detail view of <FIG>. A plurality of recesses <NUM> may extend inwardly from a surface <NUM> of the female embossing or mechanical intermeshing tooling. Although the female embossing or mechanical intermeshing tooling is illustrated on a plate, it will be understood that such tooling may also be provided on an intermeshing tooling. The projections <NUM> may have the illustrated shape, a cylindrical shape, or other suitable shape. Although the male embossing or mechanical intermeshing tooling is illustrated on a plate, it will be understood that such tooling may also be provided on an outer surface of a cylindrical roll. <FIG> is a perspective view of a plate comprising female embossing or mechanical intermeshing tooling. <FIG> is a top view of the plate comprising the female embossing or mechanical intermeshing tooling of <FIG> is detail view of <FIG>. A plurality of recesses <NUM> may extend inwardly from a surface <NUM> of the female embossing or mechanical intermeshing tooling. Although the female embossing or mechanical intermeshing tooling is illustrated on a plate, it will be understood that such tooling may also be provided on an outer surface of a roll. The male embossing or mechanical intermeshing tooling works in conjunction with the female embossing or mechanical intermeshing tooling to create the three-dimensional features in an acquisition material. The projections <NUM> of the male embossing or mechanical intermeshing tooling may partially, or fully engage the recesses <NUM> of the female embossing or mechanical intermeshing tooling to create the three-dimensional features in an acquisition material. The amount that the projections <NUM> of the male embossing or mechanical intermeshing tooling engage the recesses <NUM> of the female embossing or mechanical intermeshing tooling is known as the depth of engagement or "DOE". The depth of engagement may be varied depending on the desired three-dimensional features. A smaller depth of engagement produces shorter or smaller three-dimensional features in an acquisition material, while a larger depth of the engagement produces larger or higher three-dimensional features in an acquisition material. The recesses <NUM> may be slightly larger than the projections <NUM> to allow the projections <NUM> to fit at least partially, or fully, within the recesses <NUM>. The recesses <NUM> and the projections <NUM> may both have the same shape or may have similar shapes. The patterns of projections <NUM> and recesses <NUM> may be varied and may contain areas without projections or recesses.

<FIG> is a perspective view of an example acquisition material <NUM> of the present disclosure with three-dimensional features <NUM>. The acquisition material <NUM> may comprise one or more layers and may take on one or more of the two layer configurations illustrated in <FIG>, for example. In a single layer configuration, the three-dimensional features <NUM> may face toward the topsheet or toward the absorbent core when positioned within an absorbent article. Although tears <NUM> in the three-dimensional features <NUM> are illustrated in <FIG>, tears may not always be present in the three-dimensional features <NUM> depending on the depth of engagement of the tooling, as described below with respect to <FIG>.

The acquisition material <NUM> of <FIG> may be produced by the process and tooling illustrated in <FIG>. A pair of intermeshing rollers <NUM> and <NUM> may form a nip <NUM> through which a one or more layer acquisition material <NUM> may be conveyed to create the three-dimensional features <NUM> in the acquisition material. The intermeshing roller <NUM> may comprise a plurality of ridges <NUM> and a plurality of grooves <NUM> and may rotate about axis, A, in the direction shown by the arrow. The second intermeshing roller <NUM> may comprise a plurality of circumferentially spaced teeth <NUM> and a plurality of grooves <NUM> and may rotate about axis, A, in the direction shown by the arrow. The plurality of ridges <NUM> of the first roller <NUM> may at least partially, or fully, engage the plurality of grooves <NUM> of the second roller <NUM>. The plurality of circumferentially spaced teeth <NUM> of the second roller <NUM> may at least partially, or fully, engage the plurality of grooves <NUM> of the first roller <NUM>. The distance that the ridges <NUM> and the circumferentially spaced teeth <NUM> engage the grooves <NUM> and <NUM>, respectively, is the depth of engagement or DOE. To create larger or higher three-dimensional features <NUM> in the acquisition material, a greater depth of engagement is used. To create smaller or shorter three-dimensional features <NUM> in the acquisition material, a smaller depth of engagement is used. Typically, a larger depth of engagement is used if tears <NUM> in the three-dimensional elements <NUM> are desired and a smaller depth of engagement is used if tears <NUM> in the three-dimensional elements <NUM> are not desired. The tears <NUM> may provide easy access for low viscosity feces or waste to void space created by the three-dimensional features <NUM>, thereby reducing blowouts and waste on skin. The machine direction, MD, and the cross-machine direction, CD, are illustrated in <FIG>.

The acquisition material <NUM> shown in <FIG> may be produced by the process illustrated in <FIG>. A pair of intermeshing rollers <NUM> and <NUM> may form a nip <NUM> through which a one or more layer acquisition material <NUM> may be conveyed to create the three-dimensional features <NUM> in the acquisition material. The intermeshing roller <NUM> may comprise a plurality of ridges <NUM> and a plurality of grooves <NUM> and may rotate about axis, A, in the direction shown by the arrow. The second intermeshing roller <NUM> may comprise a plurality of ridges <NUM> and a plurality of grooves <NUM> and may rotate about axis, A, in the direction shown by the arrow. The plurality of ridges <NUM> of the first roller <NUM> may at least partially, or fully, engage the plurality of grooves <NUM> of the second roller <NUM>. The plurality of ridges <NUM> of the second roller <NUM> may at least partially, or fully, engage the plurality of grooves <NUM> of the first roller <NUM>. The distance that the ridges <NUM> and the ridges <NUM> engage the grooves <NUM> and <NUM>, respectively, is the depth of engagement. Three-dimensional features are created both on a first side of the acquisition material <NUM> and a second side of the acquisition material by the intermeshing rollers <NUM> and <NUM>. To create larger or higher three-dimensional features <NUM> in the acquisition material, a greater depth of engagement is used. To create smaller or shorter three-dimensional features <NUM> in the acquisition material, a smaller depth of engagement is used. Typically, a larger depth of engagement is used if tears <NUM> in the three-dimensional elements <NUM> are desired and a smaller depth of engagement is used if tears <NUM> in the three-dimensional elements <NUM> are not desired. The tears <NUM> may provide easy access for low viscosity feces or waste to void space created by the three-dimensional features <NUM>, thereby reducing blowouts and waste on skin. The machine direction, MD, and the cross-machine direction, CD, are illustrated in <FIG>.

As an example, the three-dimensional features discussed herein may be created via male female embossing and/or mechanical intermeshing. <FIG> an example acquisition material created by the tooling illustrated in <FIG>. <FIG> illustrate example male embossing or mechanical intermeshing tooling that may be used with the female embossing or mechanical intermeshing tooling of <FIG> to create a pattern of three-dimensional features in an acquisition material. The male-female embossing or mechanical intermeshing may be used to create void spaces in and activate or mechanically activate an acquisition material. One or more layers may be embossed or mechanical intermeshed together (see e.g., <FIG>) or single layers may be embossed or mechanical intermeshed separately. If single layers are embossed or mechanical intermeshed separately, they may optionally be joined with other embossed or mechanical intermeshed single layers to create, for example, the structure illustrated in <FIG>. Also, if single layers are embossed or mechanical intermeshed separately, they may be joined with a generally planar layer to create the structure of <FIG>.

<FIG> is a perspective view of a plate comprising male embossing or mechanical intermeshing tooling. <FIG> is a top view of the plate comprising the male embossing or mechanical intermeshing tooling of <FIG>. A plurality of projections <NUM> may extend outwardly from a surface <NUM> of the male embossing or mechanical intermeshing tooling. The projections <NUM> may have the illustrated shape forming a clover pattern. Although the male embossing or mechanical intermeshing tooling is illustrated on a plate, it will be understood that such tooling may also be provided on an outer surface of a cylindrical roll. <FIG> is a perspective view of a plate comprising female embossing or mechanical intermeshing tooling. <FIG> is a top view of the plate comprising the female embossing or mechanical intermeshing tooling of <FIG>. A plurality of recesses <NUM> may extend inwardly from a surface <NUM> of the female embossing or mechanical intermeshing tooling. Although the female embossing or mechanical intermeshing tooling is illustrated on a plate, it will be understood that such tooling may also be provided on an outer surface of a roll. The male embossing or mechanical intermeshing tooling works in conjunction with the female embossing or mechanical intermeshing tooling to create the three-dimensional features in an acquisition material. The projections <NUM> of the male embossing or mechanical intermeshing tooling may partially, or fully engage the recesses <NUM> of the female embossing or mechanical intermeshing tooling to create the three-dimensional features in an acquisition material. The amount that the projections <NUM> of the male embossing or mechanical intermeshing tooling engage the recesses <NUM> of the female embossing or mechanical intermeshing tooling is known as the depth of engagement or "DOE". The depth of engagement may be varied depending on the desired three-dimensional features. A smaller depth of engagement produces shorter or smaller three-dimensional features in an acquisition material, while a larger depth of the engagement produces larger or higher three-dimensional features in an acquisition material. The recesses <NUM> may be slightly larger than the projections <NUM> to allow the projections <NUM> to fit at least partially within the recesses <NUM>. The recesses <NUM> and the projections <NUM> that engage each other may both have the same shape or may have similar shapes. The patterns of projections <NUM> and recesses <NUM> may be varied and may contain areas without projections or recesses.

Some example processes to create the three-dimensional features in acquisition materials have been disclosed herein. These processes create high-caliper, high air permeability acquisition materials. Other processes to achieve the same or similar results comprise penetrating the acquisition material with three-dimensional pins, compressing the acquisition material in a three-dimensional die, or stretching the acquisition materials homogeneously or non-homogeneously, for example. In any of the processes, heat may be applied to the acquisition materials during activation or three-dimensional feature creation to at least partially "set" the three-dimensional shape and allow them to resist subsequent compression. This resistance to compression is helpful when packaged under pressure and during wear to maintain the high caliper and high air permeability of the acquisition materials.

Topsheets having apertures <NUM> (see <FIG>) may be used in combination with the acquisition materials of the present disclosure to form a low viscosity feces or waist acquisition system or laminate. The topsheets may be joined, bonded, glued, or otherwise attached to at least portions of the acquisition materials. In some instances, the topsheets may only be joined, bonded, glued, or otherwise attached to the acquisition materials in certain regions, while other regions remain unattached (but may still be in contact). <FIG> only illustrates the apertures <NUM> in a portion of the topsheet <NUM>, but it will be understood that the apertures may extend throughout an area of the topsheet <NUM>. The topsheets may comprise one or more layers, such as two layers. In an instance, a wearer-facing layer may be hydrophobic and a garment-facing layer may be hydrophilic. In another instance, the wearer-facing layer may be more hydrophobic than the garment-facing layer, but both may be hydrophilic. In order for the topsheets to be able to pass low viscosity feces or waste to the acquisition materials, the topsheets typically should have a certain size of apertures and the overall topsheet should have a certain Percent Effective Aperture Area. The apertures may have a size in the range of about <NUM><NUM> to about <NUM><NUM>, about <NUM><NUM> to about <NUM><NUM>, about <NUM><NUM> to about <NUM><NUM>, or about <NUM><NUM> to about <NUM><NUM>, specifically reciting all <NUM><NUM> increments within the specified ranges and all ranges formed therein or thereby, according to the Percent Effective Area Test. The topsheets may have a Percent Effective Area in the range of about <NUM>% to about <NUM>%, about <NUM>% to about <NUM>%, about <NUM>% to about <NUM>%, about <NUM>% to about <NUM>%, or about <NUM>% to about <NUM>%, specifically reciting all <NUM>% increments within the specified ranges and all ranges formed therein or thereby, according to the Perfect Effective Area Test. Generally, topsheets with greater Percent Effective Area allow more low viscosity feces or waste to reach the acquisition materials disclosed herein, thereby reducing blowouts and waste on skin. Topsheets with lower Percent Effective Areas may become a limiting factor in how much low viscosity feces or waste reaches, and is subsequently acquired and stored by, the acquisition materials.

Trans-topsheet capacity ("TTSC") is the measure of the amount of low viscosity feces or waste that can reach, and be stored in, an absorbent structure comprising an apertured topsheet and an acquisition material positioned beneath the apertured topsheet. It has been found that a TTSC of at least about <NUM>/in<NUM>, at least about <NUM>/in<NUM> or at least about <NUM>/in<NUM> is generally suitable to provide significant benefits to wearers compared to currently marketed absorbent articles. The acquisition material tested is a resin bonded material with about <NUM>% fibers, by weight of the acquisition material, and about <NUM>% latex binder, by weight of the acquisition material. The fibers are carded fibers. Each layer is <NUM> gsm. The properties of each of the samples are detailed in Chart <NUM>.

Samples <NUM>, <NUM>, and <NUM> show examples of acquisition materials of the present disclosure with certain air permeability and caliper that achieve a TTSC of at least about <NUM>/in<NUM>, and provide the benefits of the acquisition materials of present disclosure. Samples <NUM> and <NUM> are examples of acquisition materials that did not have a TTSC of at least about <NUM>/in<NUM> and, therefore, do not provide all of the benefits of the acquisition materials of the present disclosure. Sample <NUM> is related art. Sample <NUM> is an embodiment that was tested that did not achieve a suitable TTSC.

TTSC may be in the range of about <NUM>/in<NUM> to about <NUM>/in<NUM>, about <NUM>/in<NUM> to about <NUM>/in<NUM>, about <NUM>/in<NUM> to about <NUM>/in<NUM>, about <NUM>/in<NUM> to about <NUM>/in<NUM>, for example. TTSC is measured according to the Trans-topsheet Capacity Test herein.

Applicants have tested three competitive acquisition materials as set forth in Chart <NUM> below according to the Air Permeability Test and the Caliper Test herein. The competitive data shows that existing high air permeability acquisition materials are also quite thin, as compared to the acquisition materials of the present disclosure. The extreme thinness (low caliper) of the competitive art samples provide extremely low capacity for viscous bodily waste even if coupled with a topsheet having the Percent Effective Area values described herein (but the competitive absorbent articles do not have apertured topsheets meeting this criteria). Two of the samples also lack the air permeability for viscous bodily waste to even penetrate the structure adequately, even if they had sufficient capacity. These acquisition materials are not designed, or configured in a diaper, to address the viscous bodily waste needs of younger infants.

Basis weight of the materials described herein may be determined by several available techniques, but a simple representative technique involves taking an absorbent article or other consumer product, removing any elastic which may be present and stretching the absorbent article or other consumer product to its full length. A punch die having an area of <NUM><NUM> is then used to cut a piece of the material being measured from the approximate center of the absorbent article or other consumer product in a location which avoids to the greatest extent possible any adhesive which may be used to fasten the material to any other layers which may be present and removing the material from other layers (using cryogenic spray, such as Cyto-Freeze, Control Company, Houston, Texas, if needed). The sample is then weighed and dividing by the area of the punch die yields the basis weight of the material. Results are reported as a mean of <NUM> samples to the nearest <NUM> gram per square meter (gsm).

Effective aperture dimensions, percent effective area and inter-aperture distance measurements are obtained from aperture specimen images acquired using a flatbed scanner. The scanner is capable of scanning in reflectance mode at a resolution of <NUM> dpi and <NUM> bit grayscale (a suitable scanner is an Epson Perfection V750 Pro from Epson America Inc. , Long Beach CA, or equivalent). The scanner is interfaced with a computer running an image analysis program (a suitable program is ImageJ v. <NUM>, National Institute of Health, USA, or equivalent). The specimen images are distance calibrated against an acquired image of a ruler certified by NIST. The aperture specimen is backed with a black glass tile (PIN <NUM>-<NUM>-<NUM>, available from HunterLab, Reston, VA, or equivalent) prior to acquiring the image. The resulting grayscale image is then converted to a binary image via a threshold gray-level value, enabling the separation of open aperture regions from specimen material regions, and these regions analyzed using the image analysis program. All testing is performed in a conditioned room maintained at about <NUM> ± <NUM> and about <NUM> ± <NUM> % relative humidity.

To obtain a specimen, the absorbent article is taped to a rigid flat surface in a planar configuration. Any leg elastics present may be cut to facilitate laying the article flat. The outer boundary of the region lying above the absorbent core of the article is identified and marked on the apertured layer. The specimen of apertured layer is removed from the underlying layers of the article by cutting around the outer perimeter of the article with a razor blade. The apertured layer specimen is carefully removed such that its longitudinal and lateral extension is maintained to avoid distortion of the apertures. A cryogenic spray (such as Cyto-Freeze, Control Company, Houston TX, or equivalent) can be used to remove the specimen from the underlying layers if necessary. Five replicate specimens obtained from five substantially similar articles are prepared for analysis. An apertured substrate raw material is prepared for testing by extending or activating it under the same process conditions, and to the same extent, as it would be for use on the absorbent article. The samples are conditioned at about <NUM> ± <NUM> C° and about <NUM>% ± <NUM>% relative humidity for <NUM> hours prior to testing.

The ruler is placed on the scanner bed such that it is oriented parallel to the sides of the scanner glass. An image of the ruler (the calibration image) is acquired in reflectance mode at a resolution of <NUM> dpi (approximately <NUM> pixels per mm) and in <NUM>-bit grayscale. The calibration image is saved as an uncompressed TIFF format file. After obtaining the calibration image, the ruler is removed from the scanner glass and all specimens are scanned under the same scanning conditions. An apertured specimen is placed onto the center of the scanner bed, lying flat, with the outward facing surface of the specimen facing the scanner's glass surface. The corners and edges of the specimen are secured such that its original longitudinal and lateral extension, as on the article prior to removal, is restored. The specimen is oriented such that the machine direction (MD) and cross direction (CD) of the apertured specimen layer are aligned parallel with and perpendicular to the sides of the scanner's glass surface and that the resulting specimen image has the MD vertically running from top to bottom. The black glass tile is placed on top of the specimen, the scanner lid is closed, and a scanned image of the entire specimen is acquired. The specimen image is save as an uncompressed TIFF format file. The remaining four replicate specimens are scanned and saved in like fashion. Prior to analysis, all specimen images are cropped to the largest rectangular field of view contained within the apertured region which had been located above the absorbent core of the article.

The calibration image file is opened in the image analysis program and a linear distance calibration is performed using the imaged ruler. This distance calibration scale is applied to all subsequent specimen images prior to analysis. A specimen image is in the image analysis program and the distance scale is set using the distance calibration. The <NUM>-bit grayscale image is then converted to a binary image (with "zero" or "black" corresponding to the aperture regions) in the following way: If the histogram of gray level (GL) values (ranging from <NUM> to <NUM>, one bin with propensity Pi per gray level i) has exactly two local maxima, the threshold gray level value t is defined as that value for which Pt-i > Pt and Pt ≤ Pt+<NUM>. If the histogram has greater than two local maxima, the histogram is iteratively smoothed using a windowed arithmetic mean of size <NUM>, and this smoothing is performed iteratively until exactly two local maxima exist. The threshold gray level value t is defined as that value for which Pt-<NUM> > Pt and Pt ≤ Pt+<NUM>. This procedure identifies the gray level (GL) value for the minimum population located between the dark pixel peak of the aperture holes and the lighter pixel peak of the specimen material. If the histogram contains either zero or one local maximum, the method cannot proceed further, and no output parameters are defined.

Each of the discrete aperture regions is analyzed using the image analysis program. All individual aperture areas are measured and recorded to the nearest <NUM><NUM>, including partial apertures along the edges of the image. Concurrently, the equivalent diameter of each aperture area is calculated from the measured area and recorded to the nearest <NUM>. Any apertures with an area less than <NUM><NUM> are defined as "non-effective" and discarded. The remaining apertures, so-called "effective" aperture areas that include whole and partial apertures, are summed in area. This sum is then divided by the total area included in the image. This value is multiplied by <NUM>% and reported as the effective area to the nearest <NUM>%. The arithmetic mean of the equivalent areas among all "effective" apertures is calculated and recorded as the characteristic aperture equivalent area of the specimen.

The remaining four specimen images are analyzed similarly. The arithmetic mean percent effective area values for the five replicate specimens is calculated and reported to the nearest <NUM>%. Similarly, the arithmetic mean of the characteristic aperture equivalent area values for the five replicate specimens is calculated and reported to the nearest <NUM><NUM>.

The Caliper of a substrate is determined using the Caliper Test method. In the Caliper Test method, two flat, parallel surfaces are used to apply unidirectional pressure to both sides of a substrate specimen, and the resulting separation between the parallel surfaces is measured. All measurements are performed in a laboratory maintained at <NUM> ± <NUM> C° and <NUM> ± <NUM>% relative humidity and test specimens are conditioned in this environment for at least <NUM> hours prior to testing.

Two parallel surfaces at least <NUM> in<NUM> (<NUM><NUM>) in area are oriented horizontally. Five nominally equivalent rectangular specimens are taken from a substrate sample such that the length and width of each specimen is greater than the largest dimension of smaller of the parallel surfaces. (For example, if a flat, circular foot is brought against a large granite base, the length and width of each specimen is larger than the diameter of the circle such that the specimen can fill the entire gap between the circular foot and granite base during the measurement. ) A specimen is placed between the two parallel surfaces so as to completely cover the smaller parallel surface. The parallel surfaced are brought to together at a rate of <NUM> ± <NUM>/s until a pressure of <NUM> psi (<NUM> kPa) is achieved, and the separation between the plates is measured and recorded to the nearest <NUM> within <NUM> seconds. The arithmetic mean of the plate separation of the individual replicate specimens is calculated and reported as the Caliper of the substrate in units of millimeters (mm) to the nearest <NUM>.

One suitable example of apparatus for use in the Caliper Method is a Mitutoyo Digimatic Series <NUM> ID-C digital indicator (Mitutoyo America Corp. , Aurora, Illinois, USA), or equivalent, fitted with a circular flat "foot" at the end of the moving shaft of the indicator gauge. The indicator is mounted on a horizontal granite base such that the shaft of the indicator gauge is oriented vertically and the plane of the circular foot is parallel to the granite base. The circular foot is sized and weighted such that the gravitational force associated with the mass of the foot and the indicator shaft together divided by the area of the circular foot constitutes <NUM> psi of downward pressure from the circular foot on the granite base. Specimens at least as large as the circular foot are analyzed between the circular foot and granite base.

The Air Permeability of a substrate is determined according to INDA/EDANA Nonwovens Standard Procedures NWSP <NUM>. R0 (<NUM>) making use of a Textest FX3300 (Textest Instruments, Schwerzenbach, Switzerland) air permeability tester or equivalent. A test head with area <NUM><NUM> is used, and while a fixed pressure of <NUM> Pa is maintained across the substrate, air flow is measured in liters per square meter per second (l/m<NUM>/s). Five nominally equivalent specimens of a sample substrate are analyzed in this way, and the air permeability of each is recorded in l/m<NUM>/s to three significant figures. The arithmetic mean of the individual specimen results is calculated and reported as the Air Permeability in units l/m<NUM>/s to the closest <NUM>/m<NUM>/s.

Trans-topsheet capacity is measured by the following test. The apparatus <NUM> used for this measurement is illustrated in <FIG>.

A hollow stainless steel cylinder <NUM> mounted on a plate <NUM> is provided. The stainless steel cylinder <NUM> has a height of <NUM> centimeters (<NUM> inches), an inside diameter of <NUM> centimeters (<NUM> inches) and an outside diameter of <NUM> centimeters (<NUM> inches). The bottom of the cylinder <NUM> extends below the plate <NUM> a distance of <NUM> millimeters, and has a lip with an annular thickness of <NUM> millimeters. The lip <NUM> prevents the fecal material analog from leaking outside the designated test area of the sample.

Also provided is a weight <NUM> of <NUM> grams. The weight <NUM> is also cylindrically shaped and has a diameter of <NUM> centimeters (<NUM> inches), so that the weight <NUM> fits tightly within the cylinder <NUM> but may freely slide throughout the hole in the cylinder <NUM>. This arrangement provides a pressure of <NUM> kilogram-force per square meter (<NUM> pounds per square inch) and a test area of <NUM> square inches. If desired, the weight <NUM> may have a handle <NUM> to allow it to be easily inserted into and removed from the cylinder <NUM>.

An apertured topsheet <NUM> is used. The apertured topsheet is a single nonwoven layer of polyethylene/polypropylene bicomponent fibers, made by a process of overbonding and ring rolling (followed by stretching about <NUM>% in the cross-machine direction to open the apertures) as illustrated in <FIG> of <CIT> ("Benson"), and creating the apertured structure illustrated in <FIG> of Benson. The overbond pattern is illustrated in <FIG>, with <FIG> showing spacing of the overbonding nubs relative to each other in millimeters. The bicomponent fibers have a fiber denier in the range of about <NUM> to about <NUM>. The apertured topsheet has a basis weight of about <NUM> gsm. The apertured topsheet has a % Percent Effective Area of about <NUM>%, according to the Perfect Effective Area Test herein.

The apertured topsheet <NUM> is cut to a <NUM> by <NUM> centimeters (<NUM> by <NUM> inch) square size. The apertured topsheet <NUM> will remain the same for all testing, although a new apertured topsheet will be used for each repetition.

The acquisition material <NUM> and a high basis weight blotter are weighed to the nearest <NUM> grams. The apertured topsheet <NUM> is then placed on the high caliper and high air permeability acquisition material of the present disclosure <NUM>.

If the acquisition material <NUM> is cut from an absorbent article, the acquisition material <NUM> should include only the acquisition material and not portions of the absorbent core, distribution material (if provided), or the topsheet. Care must be taken when removing the acquisition material <NUM> from the absorbent article not to destroy the acquisition material <NUM> or cause unintended gross deformation of the acquisition material. If difficulty is encountered in removing the acquisition material <NUM> from the absorbent article, the acquisition material <NUM> and the surrounding portion of the absorbent article may be frozen. Freezing may be accomplished using PH100-<NUM> circuit refrigerant made by Philips ECG, Inc. of Waltham, Mass.

The acquisition material <NUM> is, in turn, placed upon a high basis weight blotter after weighing (not shown). The high basis weight blotter is made of wet-laid <NUM>% virgin cellulose fibers having a basis weight of <NUM> grams per square inch and a caliper of about <NUM> millimeters (<NUM> inches). A suitable blotter is number <NUM> filter paper made by Eaton-Dikeman Division of Knowlton Brothers of Mt. Holly Springs, Pennsylvania. The apertured topsheet is then centered on top of the acquisition material (i.e., the acquisition material is sandwiched between the topsheet and the blotter).

The cylinder <NUM> is centered on the apertured topsheet <NUM>. A syringe having an opening of <NUM> to <NUM> millimeters dispenses <NUM> cubic centimeters (manually) of test fluid through the hole in the cylinder <NUM> onto the top of the apertured topsheet <NUM>. The test fluid is an analog formulated as described below. The <NUM> gram weight <NUM> is inserted through the hole in the cylinder <NUM> and gently placed on the test fluid, rotated clockwise <NUM> degrees to evenly spread the test fluid on the surface of the topsheet, and allowed to sit for a period of <NUM> minutes.

After <NUM> minutes, the weight <NUM> is removed from the apertured topsheet <NUM>. The apertured topsheet <NUM> is removed from the acquisition material <NUM> by dragging the apertured topsheet <NUM> parallel to the acquisition material <NUM>. Both the acquisition material <NUM> and the high basis weight blotter are then weighed. The trans-topsheet capacity is the increase in combined weight of the acquisition material <NUM> and the high basis weight blotter, caused by the test fluid penetrating through the apertured topsheet <NUM> on a unit area basis, divided by the apertured topsheet <NUM> test area of <NUM> square inches. Five replicates are done and the results are reported to the nearest <NUM>/in<NUM>.

The test fluid is an analog made by mixing <NUM> percent by weight Carbopol <NUM> available from the B. Goodrich Corporation of Brecksville, Ohio, or an equivalent acrylic polymer, in distilled water for five minutes using a hand held electric mixer. The mixture is allowed to equilibrate for at least <NUM> hours and used for the trans-topsheet penetration test within <NUM> hours.

Claim 1:
An absorbent article comprising:
a liquid permeable topsheet;
a liquid impermeable backsheet;
an absorbent core disposed at least partially intermediate the topsheet and the backsheet; and
an acquisition material disposed at least partially intermediate the topsheet and the absorbent core;
wherein the acquisition material has:
a Caliper in the range of about <NUM> to about <NUM>, according to the Caliper Test; and
an Air Permeability in the range of about <NUM>,<NUM>/m<NUM>/s to about <NUM>,<NUM>/m<NUM>/s, according to the Air Permeability Test;
wherein the acquisition material comprises:
a first surface;
a second surface; and
three-dimensional features extending outwardly from the first surface;
wherein the acquisition material comprises two or more layers;
wherein the first layer and the second layer comprise the three-dimensional features, and wherein tips of the three-dimensional features of the first layer are joined with tips of the three-dimensional features of the second layer.