Patent Description:
Nonwoven webs are used in many industries, including the medical, hygiene, and cleaning industries. Absorbent articles comprising nonwoven webs are used in the hygiene industry to contain and absorb bodily exudates (i.e., urine, bowel movements, and menses) in infants, children, and adults. Absorbent articles may include, but not be limited to, diapers, pants, adult incontinence products, feminine care products, and absorbent pads. Various components of these absorbent articles comprise nonwoven webs. Some example components that comprise nonwoven webs are outer cover nonwoven materials, topsheets, waistbands, leg cuffs, waist cuffs, ears, belts, and acquisition materials, for example. Consumers desire high quality nonwoven webs that function well for their intended purpose. Texture is one aspect of nonwoven webs that consumer find beneficial. As such, some nonwoven webs comprise texture patterns.

<CIT> discloses spunbond nonwoven fabrics comprising a first surface and a second surface and at least a first and second visually discernible zone on at least one of the first and second surface. The surfaces each have a pattern with three-dimensional features each defining a microzone. Each microzone has a first region and a second region having different intensive property values. There is an intensive property value difference between a microzone of the first zone and a microzone of the second zone.

<CIT> relates to liquid-pervious sheets including a nonwoven fabric of thermoplastic synthetic fibers. One of the surfaces of the sheet is formed with crests and troughs extending in the longitudinal direction and alternating in the transverse direction to form an undulated surface having repeated undulations; while the other surface is flat.

<CIT> is concerned with nonwoven fibrous webs including a multiplicity of randomly oriented discrete fibers defining a multiplicity of non-hollow projections extending from a major surface of the nonwoven fibrous web and a multiplicity of substantially planar land areas formed between each adjoining non-hollow projection.

<CIT> relates to disposable wearing articles with an outer sheet having non-thermocompressed regions surrounded by a plurality of thermocompression-bonded spots regularly and intermittently arranged at intervals. The outer sheet is provided with a fibrous layer on the outer surface thereof and being formed of thermal adhesive crimped fibers.

<CIT>discloses spunbond nonwoven cloths comprises continuous fibers made of thermoplastic resin. The spaces between the fibers are heated and compressed using an embossing roll provided with a plurality of embossments aligned in the flow direction of the fiber and the perpendicular direction thereof.

Visually discernible texture patterns on nonwoven webs are typically imparted to the nonwoven webs via processes like embossing, where the embossed texture is very regular and makes the textured or embossed nonwoven web exhibit a very engineered appearance, texture, and feel. The texture of such nonwoven webs has visual and tactile properties which make the structure less appealing than a more traditional woven web. Consumers desire nonwoven webs to have the appearance, tactile properties, and feel of more traditional woven materials as woven materials are viewed by consumers as being softer, with tactilely pleasing textures, and of high quality. As such, nonwoven webs should be improved to reflect more characteristics of woven materials.

The present disclosure provides, in part, nonwoven webs with one or more repeat units that have the tactile properties, softness, and visual appears of woven fabrics. Stated differently, the nonwoven webs of the present disclosure provide a more clothlike feel and appearance compared to previous nonwovens.

A nonwoven web as claimed in claim <NUM> comprises a first surface; a second surface; and a repeat unit comprising a visually discernible pattern of three-dimensional features on a first surface or a second surface thereof, wherein the three-dimensional features comprise one or more first regions and a plurality of second regions. The one or more first regions are different than the plurality of second regions. The one or more first regions comprise a plurality of substantially linear segments, wherein a first group of the plurality of substantially linear segments intersects with a second group of the plurality of substantially linear segments at angles of intersection in the range of about <NUM> degrees to about <NUM> degrees, preferably about <NUM> degrees to about <NUM> degrees. The first group of the plurality of substantially linear segments have a plurality of different lengths; and wherein at least one substantially linear segment of the first group intersects three or more other substantially linear segments of the second group. These regions provide for a variation in visual, tactile, and performance properties leading to the nonwoven webs being considered clothlike or woven material like. The performance of the nonwoven webs discussed herein is further driven to be woven-like and natural looking by also comprising regions of a plurality of substantially linear segments. These two different regions of the present disclosure provide for the natural type variation found in a woven material and consequently the nonwoven webs are viewed as having the visual, tactile, and performance properties of woven materials or woven, natural fabrics.

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 nonwoven webs with one or more repeat units 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 nonwoven webs with one or more repeat units 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.

Prior to a discussion of the nonwoven webs with one or more repeat units, first absorbent articles and their features will be discussed as one possible use of the nonwoven webs. It will be understood that the nonwoven webs with one or more repeat units also have other uses in other products, such as in the medical field, the cleaning and/or dusting field, and/or the wipes field, for example.

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 nonwoven material <NUM>, such as a nonwoven web, 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> 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 nonwoven webs with the one or more repeat units may be used as nonwoven components of the belts.

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 exudates 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 webs, woven or nonwoven webs 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 U. Publication No. <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 exudates may pass through the topsheet.

The nonwoven webs with the one or more repeat units may be used as nonwoven topsheets.

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 nonwoven 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 exudates 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 exudates 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 nonwoven webs with the one or more repeat units may be used as the outer cover nonwoven material.

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 exudates 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>.

The nonwoven webs with the one or more repeat units may be used as nonwoven components of the barrier leg cuffs.

Referring to <FIG> and <FIG>, the absorbent article <NUM> may comprise one or more elastic waistbands <NUM> or non-elastic waistband. 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 exudates 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.

The nonwoven webs with the one or more repeat units may be used as nonwoven components of the waistband.

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> are typically hydrophilic materials that provide significant wicking of bodily exudates. These materials may dewater the topsheet <NUM> and quickly move bodily exudates into the absorbent core <NUM>. The acquisition materials <NUM> may comprise one or more nonwoven webs, foams, cellulosic materials, cross-linked cellulosic materials, air laid cellulosic nonwoven webs, spunlace materials, or combinations thereof, for example. In some instances, portions of the acquisition materials <NUM> may extend through portions of the topsheet <NUM>, portions of the topsheet <NUM> may extend through portions of the acquisition materials <NUM>, and/or the topsheet <NUM> may be nested with the acquisition materials <NUM>. 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 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 channels in the absorbent core <NUM>. In an example, a first acquisition material may comprise a nonwoven web and as second acquisition material may comprise a cross-linked cellulosic material.

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 nonwoven 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 nonwoven 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.

The nonwoven webs with the one or more repeat units may be used as nonwoven components of the landing zone.

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 exudates 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 web and a second nonwoven web. 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 nonwoven 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>.

The nonwoven webs with the one or more repeat units may be used as nonwoven components of the front and back ears.

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 exudates such as urine and/or BM (e.g., the sensor system <NUM> may sense variations in temperature, humidity, presence of ammonia or urea, various vapor components of the exudates (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.

The nonwoven webs with one or more repeat units may be used as nonwoven components of sanitary napkins.

The nonwoven webs with one or more repeat units, or a plurality of repeat units are now discussed. <FIG> is an example of a visually discernable pattern of three-dimensional features for a nonwoven web with a certain first region % area. <FIG> is an example of a visually discernable pattern of three-dimensional features for a nonwoven web with a certain first region % area. <FIG> is an example of a visually discernable pattern of three-dimensional features for a nonwoven web with a certain first region % area and showing a repeat unit. <FIG> illustrates the repeat unit of the visually discernable pattern of three-dimensional features of <FIG>. <FIG> is an example of a visually discernable pattern of three-dimensional features for a nonwoven web with a certain first region % area and showing a repeat unit. <FIG> illustrates the repeat unit of the visually discernable pattern of three-dimensional features of <FIG>. <FIG> is a photograph of a portion of a nonwoven web comprising a visually discernable pattern of three-dimensional features.

The various visually discernable patterns of three-dimensional features <NUM> for nonwoven webs of <FIG> each comprise one or more first regions <NUM>, or a plurality of first regions <NUM>, and a plurality of second regions <NUM>. The one or more first regions <NUM> may have a % area 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>%, relative to an entire % area of the nonwoven web comprising the visually discernable pattern of three-dimensional features, specifically reciting all <NUM>% increments within the specified ranges and all ranges formed therein or thereby. The plurality of second regions <NUM> may have a % area 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>%, relative to the entire % area of the nonwoven web comprising the visually discernable pattern of three-dimensional features, specifically reciting all <NUM>% increments within the specified ranges and all ranges formed therein or thereby. All % area measurements are according to the Pattern Analysis Test herein.

Referring to <FIG>, the visually discernable pattern of three-dimensional features <NUM> for a nonwoven web comprise one or more first regions <NUM>, or a plurality of first regions <NUM>, and a plurality of second regions <NUM>. The one or more first regions <NUM> of <FIG> may have a % area of about <NUM>%, relative to an entire % area of the nonwoven web comprising the visually discernible pattern of three-dimensional features. The plurality of second regions <NUM> may have a % area of about <NUM>% relative to the entire % area of the nonwoven web comprising the visually discernible pattern of three-dimensional features. The sum of the % areas of the one or more first regions <NUM> and the plurality of the second regions <NUM> may add up to <NUM>% or less, depending on the visually discernible pattern. In an instance when the sum is less than <NUM>%, other features may be present, such as other three-dimensional features, for example.

Referring to <FIG>, the visually discernable pattern of three-dimensional features <NUM> for a nonwoven web comprise one or more first regions <NUM>, or a plurality of first regions <NUM>, and a plurality of second regions <NUM>. The one or more first regions <NUM> of <FIG> may have a % area of about <NUM>%, relative to an entire % area of the nonwoven web comprising the visually discernible pattern of three-dimensional features. The plurality of second regions <NUM> may have a % area of about <NUM>% relative to the entire % area of the nonwoven web comprising the visually discernible pattern of three-dimensional features. The sum of % areas of the one or more first regions <NUM> and the plurality of the second regions <NUM> may add up to <NUM>% or less, depending on the visually discernible pattern. In an instance when the sum is less than <NUM>%, other features may be present, such as other three-dimensional features, for example.

<FIG> and <FIG> illustrate a repeat unit <NUM> in dash. The repeat units <NUM> are illustrated in <FIG> and <FIG>, respectively. Any nonwoven webs of the present disclosure may have one or more repeat units or a plurality of repeat units. If more than one repeat unit is provided, the repeat units may all be the same, slightly different, or different.

Referring again to <FIG>, as an example, the one or more first regions <NUM>, or the plurality of first regions <NUM>, and the plurality of second regions <NUM> are different. The one or more first regions <NUM> comprise a plurality of substantially linear segments, a plurality of linear segments, and/or a plurality of substantially linear segments and a plurality of linear segments (hereinafter referred to herein as "substantially linear segments"). The plurality of substantially linear segments may comprise a first group <NUM> of the plurality of substantially linear segments <NUM> and at least a second group <NUM> of the plurality of substantially linear segments <NUM>'. The first group <NUM> of the plurality of substantially linear segments <NUM> intersects the second group <NUM> of the plurality of substantially linear segments <NUM>' at angles of intersection. The angles of intersection are in the range of about <NUM> degrees to about <NUM> degrees, about <NUM> degrees to about <NUM> degrees, or about <NUM> degrees to about <NUM> degrees, specifically reciting all <NUM> degree increments within the specified ranges and all ranges formed therein or thereby. In certain patterns, some angles of intersection may be different while other angles of intersection may be the same.

At least one of the substantially linear segments <NUM> of the first group <NUM> of the plurality of substantially linear segments intersects at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, but less than <NUM> of the substantially linear segments <NUM>' of the second group <NUM> of the plurality of substantially linear segments. Likewise, at least one of the substantially linear segments <NUM>' of the second group <NUM> of the plurality of substantially linear segments may intersect at least two, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, but less than <NUM>, or less than <NUM>, of the substantially linear segments <NUM> of the first group <NUM> of the plurality of substantially linear segments. The substantially linear segments <NUM> in the first group <NUM> of the plurality of substantially linear segments may extend in a first direction <NUM>, or within about <NUM> degrees to about <NUM> degrees, about <NUM> degrees to about <NUM> degrees, or about <NUM> degrees to about <NUM> degrees, from the first direction <NUM>, specifically reciting all <NUM> degree increments within the specified ranges and all ranges formed therein or thereby. The substantially linear segments <NUM>' in the second group <NUM> of the plurality of linear segments may extend in a second, different direction <NUM>, or within about <NUM> degrees to about <NUM> degrees, about <NUM> degrees to about <NUM> degrees, or about <NUM> degrees to about <NUM> degrees from the second direction <NUM>, specifically reciting all <NUM> degree increments within the specified ranges and all ranges formed therein or thereby. The first direction <NUM> may be perpendicular to the second direction <NUM>. The substantially linear segments <NUM> in the first group <NUM> may extend in different directions, although still extending generally about the first direction <NUM>. Likewise, the substantially linear segments <NUM>' in the second group <NUM> may extend in different directions, although still extending generally about the second direction <NUM>.

Still referring to <FIG>, the substantially linear segments <NUM> in the first group <NUM> have a plurality of different lengths along the first direction <NUM>, although some of the substantially linear segments <NUM> may have the same length. The substantially linear segments <NUM>' in the second group <NUM> may have a plurality of different lengths along the second direction <NUM>, although some of the substantially linear segments <NUM>' may have the same length. It is envisioned that some of the substantially linear segments <NUM> in the first group <NUM> may have the same length as some of the substantially linear segments <NUM>' in the second group <NUM>. The lengths of the substantially linear segments in the first and second groups may be in the range about <NUM> to about <NUM>, 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. The substantially linear segments <NUM> in the first group <NUM> may have the same widths or different widths. Likewise, the substantially linear segments <NUM>' in the second group <NUM> may have the same widths or different widths. The width(s) of the substantially linear segments <NUM> of the first group <NUM> may be the same as or different than the width(s) of the substantially linear segments <NUM>' of the second group <NUM>. The widths of the substantially linear segments <NUM> and <NUM>' may be in the range of about <NUM> to about <NUM>, specifically reciting all <NUM> increments within the specified range.

At least some of the one or more first regions <NUM> may fully enclose or surround a second region <NUM> to form an enclosed second region <NUM>. At least some of the plurality of second regions <NUM> may form a peninsular shape.

The above descriptions with respect to <FIG> may also apply to <FIG>. The nonwoven webs comprising the visually discernable patterns of three-dimensional elements 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, about <NUM> gsm to about <NUM> gsm, according to the Basis Weight Test herein, and specifically reciting all <NUM> gsm increments within the specified ranges and all ranges formed therein or thereby.

The visually discernable pattern of three-dimensional elements may be formed in a nonwoven web by embossing, hydroentangling, or by using a structured forming belt for fiber laydown. Using embossing or hydroentangling, the first regions or the second regions may be embossed or hydroentangled to form the pattern. The structured forming belt will be discussed further below. The nonwoven webs may form a nonwoven component of an absorbent article or other consumer products, such a cleaning or dusting product, or a wipe, for example. The absorbent article (as discussed above) may comprise a liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent core positioned at least partially intermediate the topsheet and the backsheet. The absorbent article may also comprise an outer cover nonwoven material in a facing relationship with the backsheet and forming a garment-facing surface of the absorbent article. The nonwoven webs comprising the visually discernible pattern of three-dimensional features <NUM> may form a topsheet, or portion thereof, an outer cover nonwoven material, or portion thereof, a portion of a wing, a portion of an ear, a portion of a belt, a portion of leg cuff, or a portion of a waistband, for example. The nonwoven webs may also form more than one component of an absorbent article or other consumer product. The nonwoven webs may also be used in medical gowns, wound dressings, and/or other medical products comprising nonwoven components.

The plurality of second regions <NUM> of a visually discernable pattern of three-dimensional features <NUM> on a nonwoven web may comprise 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>, irregular varying regions, according to the Pattern Analysis Test herein, specifically reciting all <NUM> increments within the specified ranges and all ranges formed therein or thereby. The irregular varying regions may vary in shape and/or area.

These irregular varying regions create the impression of a natural, organic, or woven nonwoven web, which is consumer desirable. These irregular varying regions provide for a variation in visual, tactile, and performance properties leading to the nonwoven webs being considered clothlike or woven material like.

The plurality of second regions <NUM> of a visually discernable pattern of three-dimensional features <NUM> on a nonwoven web may have an Area Variability of greater than <NUM>%, but less than <NUM>%, of greater than <NUM>%, but less than <NUM>%, of greater than <NUM>%, but less than <NUM>%, or of greater than <NUM>%, but less than <NUM>%, according to the Pattern Analysis Test herein, specifically reciting all <NUM>% increments within the specified ranges and all ranges formed therein or thereby.

The area variability of the second regions create the impression of a natural, organic, or woven nonwoven web, which is consumer desirable. The area variability of the second regions provide for a variation in visual, tactile, and performance properties leading to the nonwoven webs being considered clothlike or woven material like.

The plurality of second regions <NUM> of a visually discernable pattern of three-dimensional features <NUM> on a nonwoven web may have an Shape Variability of greater than <NUM>%, but less than <NUM>%, of greater than <NUM>%, but less than <NUM>%, of greater than <NUM>%, but less than <NUM>%, or of greater than <NUM>%, but less than <NUM>%, according to the Pattern Analysis Test herein, specifically reciting all <NUM>% increments within the specified ranges and all ranges formed therein or thereby.

The shape variability of the second regions create the impression of a natural, organic, or woven nonwoven web, which is consumer desirable. The shape variability of the second regions provide for a variation in visual, tactile, and performance properties leading to the nonwoven webs being considered clothlike or woven material like.

The nonwoven webs of the present disclosure may be formed by a dry-laid process using short staple fibers and mechanical web formation, such as a carding process. The resulting webs may be bonded using irregular pattern thermal embossing or hydroforming/hydroentangling processes. The nonwoven webs may also comprise cotton or other natural fibers. The nonwoven webs of the present disclosure may also be coform webs. Coformed webs typically comprise a matrix of meltblown fibers mixed with at least one additional fibrous organic materials, such as fluff pulp, cotton, and/or rayon, for example. The coform webs may be further structured by embossing or laying down the composite on a structured belt during a coforming process. In an instance, continuous spunbond filaments are used in producing the nonwoven webs if the nonwoven webs are being made on a structured forming belt (as described below). The nonwoven webs may comprise continuous mono-component polymeric filaments comprising a primary polymeric component. The nonwoven webs may comprise continuous multicomponent polymeric filaments comprising a primary polymeric component and a secondary polymeric component. The filaments may be continuous bicomponent filaments comprising a primary polymeric component A and a secondary polymeric component B. The bicomponent filaments have a cross-section, a length, and a peripheral surface. The components A and B may be arranged in substantially distinct zones across the cross-section of the bicomponent filaments and may extend continuously along the length of the bicomponent filaments. The secondary component B constitutes at least a portion of the peripheral surface of the bicomponent filaments continuously along the length of the bicomponent filaments. The polymeric components A and B may be melt spun into multicomponent fibers on conventional melt spinning equipment. The equipment may be chosen based on the desired configuration of the multicomponent. Commercially available melt spinning equipment is available from Hills, Inc. located in Melbourne, Florida. The temperature for spinning is in the range of about <NUM>° C to about <NUM>° C. The bicomponent spunbond filaments may have an average diameter from about <NUM> microns to about <NUM> microns or from about <NUM> microns to about <NUM> microns, for example.

The components A and B may be arranged in either a side-by-side arrangement as shown in <FIG> or an eccentric sheath/core arrangement as shown in <FIG> to obtain filaments which exhibit a natural helical crimp. Alternatively, the components A and B may be arranged in a concentric sheath/core arrangement as shown in <FIG>. Additionally, the component A and B may be arranged in multi-lobal sheath/core arrangement as shown in <FIG>. Other multicomponent fibers may be produced by using the compositions and methods of the present disclosure. The bicomponent and multicomponent fibers may be segmented pie, ribbon, islands-in-the-sea configurations, or any combination thereof. The sheath may be continuous or noncontinuous around the core. The fibers of the present disclosure may have different geometries that comprise round, elliptical, star shaped, rectangular, and other various geometries. Methods for extruding multicomponent polymeric filaments into such arrangements are generally known to those of ordinary skill in the art.

A wide variety of polymers are suitable for the nonwoven webs of the present disclosure including polyolefins (such as polyethylene, polypropylene and polybutylene), polyesters, polyamides, polyurethanes, elastomeric materials, and the like. Examples of polymer materials that may be spun into filaments may comprise natural polymers.

Primary component A and secondary component B may be selected so that the resulting bicomponent filament provides improved nonwoven bonding and softness. Primary polymer component A may have melting temperature which is lower than the melting temperature of secondary polymer component B.

Primary polymer component A may comprise polyethylene, polypropylene or random copolymer of propylene and ethylene. Secondary polymer component B may comprise polypropylene or random copolymer of propylene and ethylene. Polyethylenes may comprise linear low density polyethylene and high density polyethylene. In addition, secondary polymer component B may comprise polymers, additives for enhancing the natural helical crimp of the filaments, lowering the bonding temperature of the filaments, and enhancing the abrasion resistance, strength and softness of the resulting fabric.

Inorganic fillers, such as the oxides of magnesium, aluminum, silicon, and titanium, for example, may be added as inexpensive fillers or processing aides. Pigments and/or color melt additives may also be added.

The fibers of the nonwoven webs disclosed herein may comprise a slip additive in an amount sufficient to impart the desired haptics to the fiber. As used herein, "slip additive" or "slip agent" means an external lubricant. The slip agent when melt-blended with the resin gradually exudes or migrates to the surface during cooling or after fabrication, hence forming a uniform, invisibly thin coating, thereby yielding permanent lubricating effects. The slip agent may be a fast bloom slip agent.

During the making or in a post-treatment or even in both, the nonwoven webs of the present disclosure may be treated with surfactants or other agents to either hydrophilize the web or make it hydrophobic. For example, a nonwoven web used as a topsheet may be treated with a hydrophilizing material or surfactant so as to make it permeable to body exudates, such as urine and menses. For other absorbent articles, the nonwoven webs may remain in their naturally hydrophobic state or made even more hydrophobic through the addition of a hydrophobizing material or surfactant.

Suitable materials for preparing the multicomponent filaments of the nonwoven webs of the present disclosure may comprise PP3155 polypropylene obtained from Exxon Mobil Corporation and PP3854 polypropylene obtained from Exxon Mobil Corporation.

As mentioned above, the nonwoven webs of the present disclosure may be produced by embossing, hydroentangling, or by using a structured forming belt for fiber or filament laydown. The structured forming belt and the process of manufacture will be described now. The nonwoven webs may be formed directly on the structured forming belt with continuous spunbond filaments in a single forming process. The nonwoven webs may assume a shape and texture which corresponds to the shape and texture of the structured forming belt.

The present disclosure may utilize the process of melt spinning. Melt spinning may occur from about <NUM> to about <NUM>° or from about <NUM>° to about <NUM>°, for example. Fiber spinning speeds may be greater than <NUM> meters/minute, from about <NUM>,<NUM> to about <NUM>,<NUM> meters/minute, from about <NUM>,<NUM> to about <NUM>,<NUM> meters/minute, or from about <NUM>,<NUM> to about <NUM>,<NUM> meters/minute, for example. Spinning speeds may affect the brittleness of the spun fiber, and, in general, the higher the spinning speed, the less brittle the fiber. Continuous fibers may be produced through spunbond methods or meltblowing processes.

Referring to <FIG>, a representative process line <NUM> for manufacturing some example nonwoven webs made on a structured forming belt of the present disclosure is illustrated. The process line <NUM> is arranged to produce a nonwoven web of bicomponent continuous filaments, but it should be understood that the present disclosure comprehends nonwoven webs made with monocomponent or multicomponent filaments having more than two components. The bicomponent filaments may or may not be trilobal.

The process line <NUM> may comprise a pair of extruders <NUM> and <NUM> driven by extruder drives <NUM> and <NUM>, respectively, for separately extruding the primary polymer component A and the secondary polymer component B. Polymer component A may be fed into the respective extruder <NUM> from a first hopper <NUM> and polymer component B may be fed into the respective extruder <NUM> from a second hopper <NUM>. Polymer components A and B may be fed from the extruders <NUM> and <NUM> through respective polymer conduits <NUM> and <NUM> to filters <NUM> and <NUM> and melt pumps <NUM> and <NUM>, which pump the polymer into a spin pack <NUM>. Spinnerets for extruding bicomponent filaments are generally known to those of ordinary skill in the art.

Generally described, the spin pack <NUM> comprises a housing which comprises a plurality of plates stacked one on top of the other with a pattern of openings arranged to create flow paths for directing polymer components A and B separately through the spinneret. The spin pack <NUM> has openings arranged in one or more rows. The spinneret openings form a downwardly extending curtain of filaments when the polymers are extruded through the spinneret. For the purposes of the present disclosure, spinnerets may be arranged to form side-by-side, eccentric sheath/core, or sheath/core bicomponent filaments as illustrated in <FIG>, as well as non-round fibers, such as tri-lobal fibers as shown in <FIG>. Moreover, the fibers may be monocomponent having one polymeric component, such as polypropylene, for example.

The process line <NUM> may comprises a quench blower <NUM> positioned adjacent to the curtain of filaments extending from the spinneret. Air from the quench air blower <NUM> may quench the filaments extending from the spinneret. The quench air may be directed from one side of the filament curtain or both sides of the filament curtain.

An attenuator <NUM> may be positioned below the spinneret and receives the quenched filaments. Fiber draw units or aspirators for use as attenuators in melt spinning polymers are generally known to those of skill in the art. Suitable fiber draw units for use in the process of forming the nonwoven webs of the present disclosure may comprise a linear fiber attenuator of the type shown in <CIT> and eductive guns of the type shown in <CIT> and <CIT>.

Generally described, the attenuator <NUM> may comprise an elongate vertical passage through which the filaments are drawn by aspirating air entering from the sides of the passage and flowing downwardly through the passage. A structured, endless, at least partially foraminous, forming belt <NUM> may be positioned below the attenuator <NUM> and may receive the continuous filaments from the outlet opening of the attenuator <NUM>. The forming belt <NUM> may travel around guide rollers <NUM>. A vacuum <NUM> positioned below the structured forming belt <NUM> where the filaments are deposited draws the filaments against the forming surface. Although the forming belt <NUM> is shown as a belt in <FIG>, it should be understood that the forming belt may also be in other forms such as a drum. Details of particular shaped forming belts are explained below.

In operation of the process line <NUM>, the hoppers <NUM> and <NUM> are filled with the respective polymer components A and B. Polymer components A and B are melted and extruded by the respective extruders <NUM> and <NUM> through polymer conduits <NUM> and <NUM> and the spin pack <NUM>. Although the temperatures of the molten polymers vary depending on the polymers used, when polyethylenes are used as primary component A and secondary component B respectively, the temperatures of the polymers may range from about <NUM> to about <NUM>, for example.

As the extruded filaments extend below the spinneret, a stream of air from the quench blower <NUM> at least partially quench the filaments, and, for certain filaments, to induce crystallization of molten filaments. The quench air may flow in a direction substantially perpendicular to the length of the filaments at a temperature of about <NUM> to about <NUM>° C and a velocity from about <NUM> to about <NUM> feet per minute. The filaments may be quenched sufficiently before being collected on the forming belt <NUM> so that the filaments may be arranged by the forced air passing through the filaments and the forming belt <NUM>. Quenching the filaments reduces the tackiness of the filaments so that the filaments do not adhere to one another too tightly before being bonded and may be moved or arranged on the forming belt <NUM> during collection of the filaments on the forming belt <NUM> and formation of the nonwoven web.

After quenching, the filaments are drawn into the vertical passage of the attenuator <NUM> by a flow of the fiber draw unit. The attenuator may be positioned <NUM> to <NUM> inches below the bottom of the spinneret.

The filaments may be deposited through the outlet opening of the attenuator <NUM> onto the shaped, traveling forming belt <NUM>. As the filaments are contacting the forming surface of the forming belt <NUM>, the vacuum <NUM> draws the air and filaments against the forming belt <NUM> to form a nonwoven web of continuous filaments which assumes a shape corresponding to the shape of the structured forming surface of the structured forming belt <NUM>. As discussed above, because the filaments are quenched, the filaments are not too tacky and the vacuum may move or arrange the filaments on the forming belt <NUM> as the filaments are being collected on the forming belt <NUM> and formed into nonwoven webs.

The process line <NUM> may comprise one or more bonding devices such as the cylinder-shaped compaction rolls <NUM> and <NUM>, which form a nip through which the nonwoven web may be compacted (e.g., calendared) and which may be heated to bond fibers as well. One or both of compaction rolls <NUM>, <NUM> may be heated to provide enhanced properties and benefits to the nonwoven webs by bonding portions of the nonwoven webs. For example, it is believed that heating sufficient to provide thermal bonding improves the nonwoven web's tensile properties. The compaction rolls may be pair of smooth surface stainless steel rolls with independent heating controllers. The compaction rolls may be heated by electric elements or hot oil circulation. The gap between the compaction rolls may be hydraulically controlled to impose desired pressure on the nonwoven web as it passes through the compaction rolls on the forming belt. As an example, with a forming belt caliper of <NUM>, and a spunbond nonwoven web having a basis weight of <NUM> gsm, the nip gap between the compaction rolls <NUM> and <NUM> may be about <NUM>.

An upper compaction roll <NUM> may be heated sufficiently to consolidate or melt fibers on a first surface of a nonwoven web <NUM>, to impart strength to the nonwoven web so that it may be removed from forming belt <NUM> without losing integrity. As shown in <FIG>, for example, as rolls <NUM> and <NUM> rotate in the direction indicated by the arrows, the forming belt <NUM> with the spunbond web laid down on it enter the nip formed by rolls <NUM> and <NUM>. Heated roll <NUM> may heat the portions of the nonwoven web <NUM> that are pressed against it by the raised resin elements of belt <NUM>, i.e., in regions <NUM>, to create bonded fibers <NUM> on at least the first surface of the nonwoven web <NUM>. As can be understood by the description herein, the bonded regions so formed may take the pattern of the raised elements of forming belt <NUM>. By adjusting temperature and dwell time, the bonding may be limited primarily to fibers closest to the first surface of the nonwoven web <NUM>, or thermal bonding may be achieved to a second surface. Bonding may also be a discontinuous network, for example, as point bonds <NUM>, discussed below.

The raised elements of the forming belt <NUM> may be selected to establish various network characteristics of the forming belt and the bonded regions of the nonwoven web <NUM>. The network corresponds to resin making up the raised elements of the forming belt <NUM> and may comprise substantially continuous, substantially semi-continuous, discontinuous, or combinations thereof options. These networks may be descriptive of the raised elements of the forming belt <NUM> as it pertains to their appearance or make-up in the X-Y planes of the forming belt <NUM> or the three-dimensional features of the nonwoven webs <NUM>.

After compaction, the nonwoven web <NUM> may leave the forming belt <NUM> and be calendared through a nip formed by calendar rolls <NUM>, <NUM>, after which the nonwoven web <NUM> may be wound onto a reel <NUM> or conveyed directly into a manufacturing operation for products, such as absorbent articles. As shown in the schematic cross-section of <FIG>, the calendar rolls <NUM>, <NUM> may be stainless steel rolls having an engraved pattern roll <NUM> and a smooth roll <NUM>. The engraved roll may have raised portions <NUM> that may provide for additional compaction and bonding to the nonwoven web <NUM>. Raised portions <NUM> may be a regular pattern of relatively small spaced apart "pins" that form a pattern of relatively small point bonds <NUM> in the nip of calendar rolls <NUM> and <NUM>. The percent of point bonds in the nonwoven web <NUM> may be from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>%, for example. The engraved pattern may be a plurality of closely spaced, regular, generally cylindrically-shaped, generally flat-topped pin shapes, with pin heights being in a range of about <NUM> to about <NUM> or from about <NUM> to about <NUM>, for example. Pin bonding calendar rolls may form closely spaced, regular point bonds <NUM> in the nonwoven web <NUM>, as shown in an example in <FIG>. Further bonding may be by hot-air-through bonding, for example. <FIG> shows a hearts pattern made by the same structured forming belt technology that may be used to make the nonwoven webs of the present disclosure. <FIG> is only an example of a pattern, although the visually discernable patterns comprising the three-dimensional features shown, for example, in <FIG>, are more applicable to the present disclosure.

"Point bonding", as used herein, is a method of thermally bonding a nonwoven web. This method comprises passing a web through a nip between two rolls comprising a heated male patterned or engraved metal roll and a smooth or patterned metal roll. The male patterned roll may have a plurality of raised, generally cylindrical-shaped pins that produce circular point bonds. The smooth roll may or may not be heated, depending on the application. In a nonwoven manufacturing line, the nonwoven web, which could be a non-bonded nonwoven web, is fed into the calendar nip and the fiber temperature is raised to the point for fibers to thermally fuse with each other at the tips of engraved points and against the smooth roll. The heating time is typically in the order of milliseconds. The nonwoven web properties are dependent on process settings such as roll temperatures, web line speeds, and nip pressures, all of which may be determined by the skilled person for the desired level of point bonding. Other types of point bonding known generally as hot calendar bonding may use different geometries for the bonds (other than circular shaped), such as oval, lines, circles, for example. In an example, the point bonding produces a pattern of point bonds being <NUM> diameter circles with <NUM>% overall bonding area. Other bonding shapes may have raised pins having a longest dimension across the bonding surface of a pin of from about <NUM>. <NUM> to <NUM> and the overall bonding area ranges from about <NUM>% to about <NUM>%, for example.

As shown in <FIG>, a heated compaction roll <NUM> may form a bond pattern, which may be a substantially continuous network bond pattern <NUM> (e.g., interconnected heart shaped bonds) on a first surface of the nonwoven web <NUM> (not shown in <FIG>, as it faces away from the viewer), and the engraved calendar roll <NUM> may form relatively small point bonds <NUM> on a second surface <NUM> of the nonwoven web. The point bonds <NUM> may secure loose fibers that would otherwise be prone to fuzzing or pilling during use of the nonwoven web <NUM>. The advantage of the resulting structure of the nonwoven web <NUM> is most evident when used as a topsheet or outer cover nonwoven material in an absorbent article, such as a diaper, for example. In use, in an absorbent article, a first surface of the nonwoven web <NUM> may be relatively flat (relative to second surface <NUM>) and have a relatively large amount of bonding due to the heated compaction roll forming bonds <NUM> at the areas of the nonwoven web pressed by the raised elements of the forming belt <NUM>. This bonding gives the nonwoven web <NUM> structural integrity, but still may be relatively stiff or rough to the skin of a user. Therefore, a first surface of the nonwoven web <NUM> may be oriented in a diaper or sanitary napkin to face the interior of the article, i.e., away from the body of the wearer or garment-facing. Likewise, the second surface <NUM> may be wearer-facing in use, and in contact with the body. The relatively small point bonds <NUM> may be less likely to be perceived visually or tacitly by the user, and the relatively soft three-dimensional features may remain visually free of fuzzing and pilling while feeling soft to the body in use. Further bonding may be used instead of, or in addition to, the above-mentioned bonding. Through-air bonding may also be used.

The forming belt <NUM> may be made according to the methods and processes described in <CIT>, or <CIT>, or <CIT>, or <CIT>, each with the improved features and patterns disclosed herein for making spunbond nonwoven webs. The Lindsay, Trokhan, Burazin, and Stage disclosures describe structured forming belts that are representative of papermaking belts made with cured resin on a woven reinforcing member, which belts, with improvements, may be utilized to form the nonwoven webs of the present disclosure as described herein.

An example of a structured forming belt <NUM>, and which may be made according to the disclosure of <CIT>, is shown in <FIG>. As taught therein, a reinforcing member <NUM> (such as a woven belt of filaments <NUM>) is thoroughly coated with a liquid photosensitive polymeric resin to a preselected thickness. A film or negative mask incorporating the desired raised element pattern repeating elements (e.g., <FIG>) is juxtaposed on the liquid photosensitive resin. The resin is then exposed to light of an appropriate wave length through the film, such as UV light for a UV-curable resin. This exposure to light causes curing of the resin in the exposed areas (i.e., white portions or non-printed portions in the mask). Uncured resin (resin under the opaque portions in the mask) is removed from the system leaving behind the cured resin forming the pattern illustrated, for example, the cured resin elements <NUM> shown in <FIG>. Other patterns may also be formed, such as the patterns illustrated in <FIG>.

The forming belt <NUM> may comprise cured resin elements <NUM> on a woven reinforcing member <NUM>. The reinforcing member <NUM> may be made of woven filaments <NUM> as is generally known in the art of papermaking belts, including resin coated papermaking belts. The cured resin elements may have the general structure depicted in <FIG>, and are made by the use of a mask <NUM> having the dimensions indicated in Fig. <NUM> As shown in schematic cross-section in <FIG>, cured resin elements <NUM> flow around and are cured to "lock on" to the reinforcing member <NUM> and may have a width at a distal end DW of about <NUM> inches to about <NUM> inches, or from about <NUM> inches to about <NUM> inches, and a total height above the reinforcing member <NUM>, referred to as over burden, OB, of about <NUM> inches to about <NUM> inches or about <NUM> inches to about <NUM> inches, or about <NUM> inches. <FIG> represents a portion of a mask <NUM> showing the design and representative dimensions for one repeat unit of the repeating hearts design, shown herein merely as an example. The white portion <NUM> is transparent to UV light, and in the process of making the belt, as described in <CIT>, permits UV light to cure an underlying layer of resin which is cured to form the raised elements <NUM> on the reinforcing member <NUM>. After the uncured resin is washed away, the forming belt <NUM> having a cured resin design as shown in <FIG> is produced by seaming the ends of a length of the forming belt, the length of which may be determined by the design of the apparatus, as depicted in <FIG>.

Now that the generally process and forming belt have been described, examples of masks and forming belts of the nonwoven webs comprising visually discernable patterns of three-dimensional elements are disclosed in <FIG>. <FIG> is an example of a mask <NUM> for producing a structured forming belt. The central portion <NUM> of the mask <NUM> illustrates the visually discernable patterns shown generally in <FIG>. <FIG> is an example of a portion of a structured forming belt <NUM> for producing the nonwoven webs of the present disclosure. <FIG> is an example nonwoven web <NUM> of the present disclosure, where the central portion <NUM> has the visually discernible pattern shown generally in <FIG>.

Referring to <FIG>, the white portions of the mask <NUM> will form raised areas of resin on the structured forming belt <NUM>, while the black portions will not be cured and will be washed away from the structured forming belt <NUM>. In another form, the white and black portions could be reversed, and the visually discernible pattern would be formed where cured resin is not present on the belt. <FIG> illustrates the portion of structured forming belt pattern <NUM> of the central portion <NUM> of the mask <NUM>. In this instance, the raised portions have resin, while the other portions do not.

The nonwoven webs comprising the visually discernible patterns of three-dimensional elements of the present disclosure may also have other visually discernible patterns of three-dimensional features <NUM>, <NUM>, <NUM>, as shown in <FIG> and <FIG>. While the other patterns may be embossed or hydroentangled, they may also be formed using the structured forming belts described herein and process thereof. The other (or second, third, and fourth) visually discernible patterns of three-dimensional features <NUM>, <NUM>, and <NUM> may each comprise a microzone comprising a first region <NUM> and a second region <NUM> (visually discernible pattern <NUM> is used an example). The first region <NUM> may be formed where black is present on the mask <NUM> and the second region <NUM> may be formed where white is present on the mask <NUM>. As such, the first region <NUM> may be less densified than the second region <NUM>. The first region <NUM> may have an average intensive property having a first value and the second region <NUM> may have the average intensive property having a second value. The first value may be different than the second value. The average intensive property may be caliper, basis weight, or volumetric density. The other visually discernible patterns of three-dimensional features may include a different pattern of <FIG> vs. completely different pattern as shown in <FIG>.

Referring now to the central portion <NUM> of the nonwoven web <NUM> of <FIG>, the visually discernible pattern of three-dimensional features may comprise first regions <NUM> (substantially linear segments) and second regions <NUM> (regions surrounding the substantially linear elements). The first regions <NUM> may have an average intensive property having a first value and the second regions <NUM> may have the average intensive property having a second value. The first and second values may be different. The average intensive property may be caliper, basis weight, or volumetric density.

The nonwoven webs disclosed herein may be fluid permeable. The entire nonwoven web may be considered fluid permeable or some regions may be fluid permeable. By fluid permeable, as used herein, with respect to the nonwoven web is meant that the nonwoven web has at least one region which permits liquid to pass through under in-use conditions of a consumer product or absorbent article. For example, if used as a topsheet on a disposable absorbent article, the nonwoven web may have at least one zone having a level of fluid permeability permitting urine to pass through to an underlying absorbent core. By fluid permeable as used herein with respect to a region is meant that the region exhibits a porous structure that permits liquid to pass through.

Referring again to <FIG>, an example nonwoven web of the present disclosure is illustrated. The nonwoven web has a plurality of visually discernible patterns of three-dimensional elements comprising first regions <NUM> and second regions <NUM>. The first and second regions of each of the patterns <NUM>, <NUM>, <NUM>, <NUM> are recognizably different visually. A visually discernible difference exists if an observer in ordinary indoor lighting conditions (<NUM>/<NUM> vision, lighting sufficient to read by, for example) may visually discern a pattern difference between the zones, such as the first region <NUM> and the second region <NUM> of pattern <NUM>.

Because of the nature of the structured forming belts and other apparatus elements, as described herein, the three-dimensional features of the nonwoven web have average intensive properties that may differ between first and second regions, or from feature to feature in ways that provide for beneficial properties of the nonwoven web when used in personal care articles, garments, medical products, and cleaning products. For example, a first region may have a basis weight or density that is different from the basis weight or density of a second region, and both may have a basis weight or density that is different from that of a third region, providing for beneficial aesthetic and functional properties related to fluid acquisition, distribution and/or absorption in diapers or sanitary napkins.

The average intensive property differential between the various regions of the nonwoven webs is believed to be due to the fiber distribution and compaction resulting from the apparatus and method described herein. The fiber distribution occurs during the fiber laydown process, as opposed to, for example, a post making process such as embossing processes. Because the fibers are free to move during a process such as a melt spinning process, with the movement determined by the nature of the features and air permeability of the forming belt and other processing parameters, the fibers are believed to be more stable and permanently formed in nonwoven web.

In structured forming belts having multiple zones, the air permeability in each zone may be variable such that the intensive properties of average basis weight and average volumetric density in the zones may be varied. Variable air permeabilities in the various zones causes fiber movement during laydown. The air permeability may be between about <NUM> to about <NUM> cfm, or between about <NUM> to about <NUM> cfm, or between about <NUM> cfm and about <NUM> cfm, or between about <NUM> to about <NUM> cfm, specifically reciting all 1cfm increments within the specified ranges and all ranges formed therein or thereby.

The Air Permeability Test is used to determine the level of air flow in cubic feet per minute (cfm) through a forming belt. The Air Permeability Test is performed on a Texas Instruments model FX3360 Portair Air Permeability Tester, available from Textest AG, Sonnenbergstrasse <NUM>, CH <NUM> Schwerzenbach, Switzerland. The unit utilizes a <NUM> orifice plate for air permeability ranges between <NUM>-<NUM> cfm. If air permeability is lower than <NUM> cfm the orifice plate needs to be reduced; if higher than <NUM> cfm the orifice plate needs to be increased. Air permeability can be measured in localized zones of a forming belt to determine differences in air permeability across a forming belt.

Basis weight of the nonwoven webs 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 nonwoven web (e.g., topsheet, outer cover) 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 nonwoven web to any other layers which may be present and removing the nonwoven web 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 nonwoven web. Results are reported as a mean of <NUM> samples to the nearest <NUM> gram per square meter (gsm).

Area Variability and Shape Variability are obtained by analysis of a repeat unit within a scaled binary image of a pattern intended to be imparted to a nonwoven web by bonding, embossing, hydroentangling, or by a structured forming belt thereby creating a visually discernible pattern of three-dimensional features comprising one or more first regions, or a plurality of first regions, and a plurality of individual discrete second regions. For the purposes of this method, all patterns and distances are taken to be based on the projection of the bonding, embossing, hydroentangling, or structured forming belt pattern onto a two-dimensional plane.

A test region is identified as the region containing a single distinct repeating pattern. If the test region does not contain a repeat unit, then the entire test region is analyzed as a single repeat unit. A single repeat unit (hereafter "SRU") (for subsequent dimensional measurement) within the test region having the repeating pattern comprising the plurality of repeating units is defined as follows. An arbitrary point within the pattern is identified, referred to hereafter as the "chosen point" (hereafter "CP"). Any other point in the test region recognized to be in an equivalent position based on the translational symmetry of the repeat units is referred to as an "equivalent point" (hereafter "EP"). The SRU is defined as the set of points that are closer (via Euclidean distance) to the center of the CP than to the center of any other EP in the test region. The SRU identified for measurement must not touch the edge of the test region. After finding all points within the SRU, if it is found that the SRU touches the edge of the test region, this procedure is repeated with an alternative CP. The process is repeated until a SRU that does not touch the edge of the test region is identified.

One approach to determining the set of points of a SRU is based on identifying a polygonal boundary. Referring to <FIG>, the boundary of the SRU is the convex polygon formed by the intersection of line segments that immediately border the topsheet region containing the CP. The line segments are identified from lines drawn perpendicular to the midpoint of lines connecting the center of the CP to the center of all neighboring and nearby EP.

Referring to <FIG>, the SRU length (L) is defined as the feret diameter parallel to the longitudinal axis of the absorbent article, and the SRU width (W) is defined as the feret diameter parallel to the lateral axis of the absorbent article. The feret diameter is the distance between two parallel lines, both of which are tangential to the boundary of the SRU, and is recorded to the nearest <NUM>.

The boundaries of the individual discrete second regions bounded by and contained within the SRU are identified. The perimeters and areas of each of the second regions is recorded, as well as, the total count of the number of the identified irregular and varying second regions contained within the SRU.

Area Variability is the ratio of the area mean absolute deviation around the mean to the mean area expressed as a percentage and is calculated according to the following equation: <MAT> Where n is the number of individual second regions, xi are the individual second region areas, and x is the arithmetic mean of all of the areas. The Area Variability is recorded to the nearest whole percent.

A shape complexity value is the ratio of a second region's perimeter squared to its area, and is calculated according to the following equation: <MAT>.

Shape Variability is the ratio of the shape complexity mean absolute deviation around the mean to the mean shape complexity expressed as a percentage, and is calculated according to the following equation: <MAT> Where n is the number of individual second regions, yi are the individual second region shape complexity values, and y is the arithmetic mean of all of the shape complexity values. The Shape Variability is recorded to the nearest whole percent.

The percent area of the second regions within a repeat unit is calculated by first measuring the total interior area of the SRU. The areas of all the individual second regions, or portions thereof, located within the SRU are identified, summed together, and then divided by the total area of the SRU. The percent area of the second regions is calculated according to the following equation: <MAT>.

The percent area of the second regions is recorded to the nearest whole percent.

The percent area of the fist region within the repeat unit is calculated according to the following equation: <MAT>.

Repeat this procedure on five separate and distinct repeat unit areas. Report each of the measurements as the arithmetic mean of the five replicates.

The micro-CT intensive property measurement method measures the basis weight, thickness and volumetric density values within visually discernable regions of a substrate sample. It is based on analysis of a 3D x-ray sample image obtained on a micro-CT instrument (a suitable instrument is the Scanco µCT <NUM> available from Scanco Medical AG, Switzerland, or equivalent). The micro-CT instrument is a cone beam microtomograph with a shielded cabinet. A maintenance free x-ray tube is used as the source with an adjustable diameter focal spot. The x-ray beam passes through the sample, where some of the x-rays are attenuated by the sample. The extent of attenuation correlates to the mass of material the x-rays have to pass through. The transmitted x-rays continue on to the digital detector array and generate a 2D projection image of the sample. A 3D image of the sample is generated by collecting several individual projection images of the sample as it is rotated, which are then reconstructed into a single 3D image. The instrument is interfaced with a computer running software to control the image acquisition and save the raw data. The 3D image is then analyzed using image analysis software (a suitable image analysis software is MATLAB available from The Mathworks, Inc. , Natick, MA, or equivalent) to measure the basis weight, thickness and volumetric density intensive properties of regions within the sample.

To obtain a sample for measurement, lay a single layer of the dry substrate material out flat and die cut a circular piece with a diameter of <NUM>.

If the substrate material is a layer of an absorbent article, for example a topsheet, outer cover nonwoven web, acquisition layer, distribution layer, or another component layer; tape the absorbent article to a rigid flat surface in a planar configuration. Carefully separate the individual substrate layer from the absorbent article. A scalpel and/or cryogenic spray (such as Cyto-Freeze, Control Company, Houston TX) can be used to remove a substrate layer from additional underlying layers, if necessary, to avoid any longitudinal and lateral extension of the material. Once the substrate layer has been removed from the article proceed with die cutting the sample as described above.

If the substrate material is in the form of a wet wipe, open a new package of wet wipes and remove the entire stack from the package. Remove a single wipe from the middle of the stack, lay it out flat and allow it to dry completely prior to die cutting the sample for analysis.

A sample may be cut from any location containing the visually discernible zone to be analyzed. Within a zone, regions to be analyzed are ones associated with a three-dimensional feature defining a microzone. The microzone comprises a least two visually discernible regions. A zone, three-dimensional feature, or microzone may be visually discernable due to changes in texture, elevation, or thickness. Regions within different samples taken from the same substrate material may be analyzed and compared to each other. Care should be taken to avoid folds, wrinkles or tears when selecting a location for sampling.

Set up and calibrate the micro-CT instrument according to the manufacturer's specifications. Place the sample into the appropriate holder, between two rings of low density material, which have an inner diameter of <NUM>. This will allow the central portion of the sample to lay horizontal and be scanned without having any other materials directly adjacent to its upper and lower surfaces. Measurements should be taken in this region. The 3D image field of view is approximately <NUM> on each side in the xy-plane with a resolution of approximately <NUM> by <NUM> pixels, and with a sufficient number of <NUM> micron thick slices collected to fully include the z-direction of the sample. The reconstructed 3D image resolution contains isotropic voxels of <NUM> microns. Images are acquired with the source at <NUM> kVp and <NUM>µA with no additional low energy filter. These current and voltage settings may be optimized to produce the maximum contrast in the projection data with sufficient x-ray penetration through the sample, but once optimized held constant for all substantially similar samples. A total of <NUM> projections images are obtained with an integration time of <NUM> and <NUM> averages. The projection images are reconstructed into the 3D image, and saved in <NUM>-bit RAW format to preserve the full detector output signal for analysis.

Load the 3D image into the image analysis software. Threshold the 3D image at a value which separates, and removes, the background signal due to air, but maintains the signal from the sample fibers within the substrate.

Three 2D intensive property images are generated from the threshold 3D image. The first is the Basis Weight Image. To generate this image, the value for each voxel in an xy-plane slice is summed with all of its corresponding voxel values in the other z-direction slices containing signal from the sample. This creates a 2D image where each pixel now has a value equal to the cumulative signal through the entire sample.

In order to convert the raw data values in the Basis Weight Image into real values a basis weight calibration curve is generated. Obtain a substrate that is of substantially similar composition as the sample being analyzed and has a uniform basis weight. Follow the procedures described above to obtain at least ten replicate samples of the calibration curve substrate. Accurately measure the basis weight, by taking the mass to the nearest <NUM> and dividing by the sample area and converting to grams per square meter (gsm), of each of the single layer calibration samples and calculate the average to the nearest <NUM> gsm. Following the procedures described above, acquire a micro-CT image of a single layer of the calibration sample substrate. Following the procedure described above process the micro-CT image, and generate a Basis Weight Image containing raw data values. The real basis weight value for this sample is the average basis weight value measured on the calibration samples. Next, stack two layers of the calibration substrate samples on top of each other, and acquire a micro-CT image of the two layers of calibration substrate. Generate a basis weight raw data image of both layers together, whose real basis weight value is equal to twice the average basis weight value measured on the calibration samples. Repeat this procedure of stacking single layers of the calibration substrate, acquiring a micro-CT image of all of the layers, generating a raw data basis weight image of all of the layers, the real basis weight value of which is equal to the number of layers times the average basis weight value measured on the calibration samples. A total of at least four different basis weight calibration images are obtained. The basis weight values of the calibration samples must include values above and below the basis weight values of the original sample being analyzed to ensure an accurate calibration. The calibration curve is generated by performing a linear regression on the raw data versus the real basis weight values for the four calibration samples. This linear regression must have an R2 value of at least <NUM>, if not repeat the entire calibration procedure. This calibration curve is now used to convert the raw data values into real basis weights.

The second intensive property 2D image is the Thickness Image. To generate this image the upper and lower surfaces of the sample are identified, and the distance between these surfaces is calculated giving the sample thickness. The upper surface of the sample is identified by starting at the uppermost z-direction slice and evaluating each slice going through the sample to locate the z-direction voxel for all pixel positions in the xy-plane where sample signal was first detected. The same procedure is followed for identifying the lower surface of the sample, except the z-direction voxels located are all the positions in the xy-plane where sample signal was last detected. Once the upper and lower surfaces have been identified they are smoothed with a 15x15 median filter to remove signal from stray fibers. The 2D Thickness Image is then generated by counting the number of voxels that exist between the upper and lower surfaces for each of the pixel positions in the xy-plane. This raw thickness value is then converted to actual distance, in microns, by multiplying the voxel count by the <NUM> slice thickness resolution.

The third intensive property 2D image is the Volumetric Density Image. To generate this image, divide each xy-plane pixel value in the Basis Weight Image, in units of gsm, by the corresponding pixel in the Thickness Image, in units of microns. The units of the Volumetric Density Image are grams per cubic centimeter (g/cc).

Begin by identifying the region to be analyzed. A region to be analyzed is one associated with a three-dimensional feature defining a microzone. The microzone comprises a least two visually discernible regions. A zone, three-dimensional feature, or microzone may be visually discernable due to changes in texture, elevation, or thickness. Next, identify the boundary of the region to be analyzed. The boundary of a region is identified by visual discernment of differences in intensive properties when compared to other regions within the sample. For example, a region boundary can be identified based by visually discerning a thickness difference when compared to another region in the sample. Any of the intensive properties can be used to discern region boundaries on either the physical sample itself of any of the micro-CT intensive property images. Once the boundary of the region has been identified, draw an oval or circular "region of interest" (ROI) within the interior of the region. The ROI should have an area of at least <NUM> mm2, and be selected to measure an area with intensive property values representative of the identified region. From each of the three intensive property images calculate the average basis weight, thickness and volumetric density within the ROI. Record these values as the region's basis weight to the nearest <NUM> gsm, thickness to the nearest <NUM> micron and volumetric density to the nearest <NUM>/cc.

Claim 1:
A nonwoven web for an absorbent article, the nonwoven web comprising:
a first surface;
a second surface; and
a repeat unit comprising:
a visually discernible pattern of three-dimensional features on the first surface or the second surface, wherein the three-dimensional features comprise one or more first regions and a plurality of second regions;
wherein the one or more first regions are different than the plurality of second regions;
wherein the one or more first regions comprise a plurality of substantially linear segments;
wherein a first group of the plurality of substantially linear segments intersects with a second group of the plurality of substantially linear segments at angles of intersection; and
wherein the angles of intersection are in the range of about <NUM> degrees to about <NUM> degrees, preferably about <NUM> degrees to about <NUM> degrees;
wherein the first group of the plurality of substantially linear segments have a plurality of different lengths; and
wherein at least one substantially linear segment of the first group intersects three or more other substantially linear segments of the second group.