Patent Description:
Absorbent articles are used to contain and absorb bodily exudates (i.e., urine, bowel movements, and menses). Absorbent articles may take on the form of diapers, pants, adult incontinence garments, sanitary napkins, and/or tampons, for example. These absorbent articles typically 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 articles may also comprise an acquisition layer or a secondary topsheet positioned at least partially intermediate the topsheet and the absorbent core. Some current apertured topsheets (ATS) for absorbent articles employ a fully hydrophobic nonwoven topsheet with large apertures (e.g., <NUM>-<NUM><NUM>) and a high open area (e.g., <NUM>%) to deliver a clean and dry topsheet. The large apertures allow for rapid bodily exudate acquisition, while the hydrophobic fibers enable low rewet and prevent, or at least inhibit, bodily exudate retention in the topsheet. Typically, smaller apertures (e.g., less than <NUM><NUM> or less than <NUM><NUM>) cannot be provided in fully hydrophobic topsheets because the bodily exudates will not penetrate through the smaller apertures owing to surface tensions and viscosities of the bodily exudates. Smaller apertures e.g., less than <NUM><NUM> or less than <NUM><NUM> and lower open areas (e.g.. , less than <NUM>%, or less than <NUM>%), however, may be desired in topsheets for softness and aesthetics (i.e., patterning). In order to maintain sufficient bodily exudate handling, some absorbent article manufacturers have utilized a dual layer topsheet approach (hydrophobic layer over a hydrophilic layer) with these smaller apertures and reduced open areas. In order to reduce costs and complexities, it is desired to provide a single layer web or topsheet that can still deliver the same bodily exudate handling and aesthetics as two layer laminates and with the smaller apertures and the smaller open areas. Additionally, it is desired to selectively "activate" hydrophilic character only in selected regions of webs or topsheets in order to better control bodily exudate movement. Alternatively, it may be desired to selectively activate hydrophobic character only in selected regions of webs or topsheets, with the rest of the webs or topsheets remaining hydrophilic. Therefore, webs and topsheets should be improved.

< <CIT> relates to a nonwoven web which can be converted to an apertured web by stretching. In its initial non-apertured state, the web comprises a plurality of multicomponent fibers comprising at least two thermoplastic polymer components arranged in at least first and second separate continuous structured domains. The polymer component of the first domain comprises polyethylene. Prior to stretch aperturing, the web has a peak elongation of at least <NUM> percent and is characterized by having a plurality of discrete, spaced-apart, frangible bond sites of polymer bonding the fibers to form a coherent extensible nonwoven web.

<CIT> discloses an absorbent material comprising a nonwoven provided with two opposite faces, a first face intended to face the area from which the fluid to be absorbed arrives and a second opposite face. The nonwoven has a first fibrous layer defining the first face, and a second fibrous layer secured to said first layer on the opposite side. At least a part of the fibers of the first layer are hydrophobic, and at least a part of the fibers of t secondhe layer are hydrophilic.

<CIT> is concerned with apertured nonwoven webs wherein the apertures in the web are treated with an active substance such that the inner surface of the aperture differs in properties, characteristics or appearance from a surface of the web adjacent to the aperture.

<CIT> relates to material webs suitable for use in conjunction with disposable absorbent articles. The material webs comprise a melt additive that when subjected to thermal energy may be encouraged to bloom across the entirety of the web or in localized areas of the web where localized thermal energy is applied.

<CIT> discloses nonwoven webs which include multicomponent fibers bonded by a multiplicity of bond sites to form a coherent web. The multicomponent fibers include a first component formed of a hydrophobic polypropylene and a second component formed of a blend of a hydrophobic polyolefin and a hydrophilic melt additive.

The present disclosure provides webs or topsheets for absorbent articles that overcome the drawbacks of large apertured, hydrophobic topsheets (ATS) and smaller apertured dual layer topsheets (hydrophobic layer over hydrophilic layer) by providing a single layer web or topsheet that comprises discrete zones of modified surface energy. The webs or topsheet may also comprise continuous land areas or a plurality of land areas that may or may not be continuous. The webs or topsheets may comprise fibers. The fibers may comprise bicomponent fibers each comprising a first component and a second component. At least some of the first components may comprise a hydrophobic resin or a hydrophobic melt additive. At least some of the second components may comprise a hydrophilic resin or a hydrophilic melt additive. At least some of the discrete zones of modified surface energy comprising the bicomponent fibers may be surrounded by the continuous land area. In the continuous land area, the second components may not be exposed to maintain the continuous land area hydrophobic, even after any spontaneous blooming of the hydrophilic melt additive in the second components. In at least some of the discrete zones of modified surface energy, the second components may be at least partially exposed (not relating to spontaneous blooming of the hydrophilic melt additive) to render the discrete zones of modified surface energy hydrophilic, or at least partially hydrophilic. The discrete zones of modified surface energy are not created by a hydrophilic melt additive and/or a spontaneously blooming. Instead, these discrete zones of modified surface energy are created/exposed by heat and/or energy after any spontaneous blooming of the hydrophilic melt additive and/or the hydrophobic melt additive occurs and the blooming reaches some equilibrium state. By providing bicomponent fibers with the first and second components having different hydrophilicities, the discrete zones of modified surface energy may have a different hydrophilicity than the continuous land area surrounding them or the plurality of land areas. This can be accomplished in a single layer web compared to a dual layer web (i.e., hydrophobic layer over hydrophilic layer), which can save significant material costs. In the single layer apertured web or topsheet context, the apertures may be smaller than the large apertures in ATS to promote softness and aesthetics (e.g., patterning). Perimeters of the apertures, or portions thereof, may correspond to the discrete zones of modified surface energy, whether pin apertured, overbonded and ring rolled to form apertures, or formed by other aperturing processes. The single layer web or topsheet may have discrete zones of modified surface energy without the use of a topical surface energy modifying treatments or printed surface energy modifying treatments. Stated another way, the single layer web or topsheet may be free of topical or printed surface energy modifying treatments. It is noted, however, that this does not exclude a lotion etc. from being applied to the webs or topsheets.

The present disclosure is directed to an absorbent article as defined by claim <NUM> and comprising a nonwoven topsheet, a backsheet, and an absorbent core positioned at least partially intermediate the topsheet and the backsheet. The topsheet is a single layer material The nonwoven topsheet comprises a plurality of bicomponent fibers forming the nonwoven topsheet. At least some of the bicomponent fibers each comprise a first component and a second inner component. The first outer component comprises a hydrophobic melt additive and the second component comprises a hydrophilic melt additive. The nonwoven topsheet comprises a continuous land area comprising the bicomponent fibers and discrete zones of modified surface energy comprising the bicomponent fibers. At least a majority of the discrete zones of modified surface energy are surrounded by the continuous land area. In the continuous land area, the second component are not exposed to maintain the continuous land area hydrophobic. In at least some of the discrete zones of modified surface energy, the second component are at least partially exposed to render the discrete zones of modified surface energy hydrophilic. The topsheet may be free of topical or printed surface energy modifying treatments.

The present disclosure is also directed to a method of manufacturing such nonwoven topsheet.

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 webs for absorbent articles and methods for making the same 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 webs for absorbent articles and methods for making the same 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.

As used herein "hydrophilic" and "hydrophobic" have meanings well established in the art with respect to the contact angle of a referenced liquid on the surface of a material. Thus, a material having a liquid (water) contact angle of greater than about <NUM> degrees is considered hydrophobic, and a material having a liquid (water) contact angle of less than about <NUM> degrees is considered hydrophilic.

Initially, a general description of example absorbent articles will be provided and then the webs or topsheet for absorbent articles and methods of making the same will be discussed. The webs may be used in consumer products other than absorbent articles. The webs for absorbent articles may form a topsheet, an acquisition layer, a distribution layer, a secondary topsheet, a core cover, a portion of an elastic belt, other suitable layers, or a web in a consumer products other than absorbent articles.

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

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

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

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

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

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

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

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

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

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

The front and back belts <NUM> and <NUM> may comprise graphics (see e.g., <NUM> of <FIG>). The graphics may extend substantially around the entire circumference of the absorbent article <NUM> and may be disposed across side seams <NUM> and/or across proximal front and back belt seams <NUM> and <NUM>; or, alternatively, adjacent to the seams <NUM>, <NUM>, and <NUM> in the manner described in <CIT> 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>. Suitable forms of pants comprising discrete side panels are disclosed in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>.

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 continuous fibers (e.g., spunbond), carded fibers, cotton fibers, other natural fibers, for example. The topsheet may comprise through-air bonded nonwoven materials. Some topsheets are apertured (<FIG>, element <NUM>).

The topsheet may comprise one of the webs discussed herein or may form a portion of the laminate for an absorbent article in combination with another layer for example. In some forms, the topsheet may form a single layer as discussed herein.

The backsheet <NUM> is generally that portion of the absorbent article <NUM> positioned proximate to the garment-facing surface of the absorbent core <NUM>. The backsheet <NUM> may be joined to portions of the topsheet <NUM>, the outer cover material <NUM>, the absorbent core <NUM>, and/or any other layers of the absorbent article by any attachment methods known to those of skill in the art. The backsheet <NUM> prevents, or at least inhibits, the bodily 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 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 material <NUM> forms at least a portion of the garment-facing surface <NUM> of the absorbent article <NUM> and effectively "covers" the backsheet <NUM> so that film is not present on the garment-facing surface <NUM>. The outer cover material <NUM> may comprise a bond pattern, apertures, and/or three-dimensional elements. The outer cover material may comprise the webs discussed herein.

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>.

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

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

Referring to <FIG>, the absorbent articles <NUM> of the present disclosure may comprise graphics <NUM> and/or wetness indicators <NUM> that are visible from the garment-facing surface <NUM>. The graphics <NUM> may be printed on the landing zone <NUM>, the backsheet <NUM>, and/or at other locations. The wetness indicators <NUM> are typically applied to the absorbent core facing side of the backsheet <NUM>, so that they can be contacted by bodily 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 material and a second nonwoven material. The elastic film may or may not be apertured. The ears may be shaped. The ears may be integral (e.g., extension of the outer cover material <NUM>, the backsheet <NUM>, and/or the topsheet <NUM>) or may be discrete components attached to a chassis <NUM> of the absorbent article on a wearer-facing surface <NUM>, on the garment-facing surface <NUM>, or intermediate the two surfaces <NUM>, <NUM>.

Referring again to <FIG>, the absorbent articles of the present disclosure may comprise a sensor system <NUM> for monitoring changes within the absorbent article <NUM>. The sensor system <NUM> may be discrete from or integral with the absorbent article <NUM>. The absorbent article <NUM> may comprise sensors that can sense various aspects of the absorbent article <NUM> associated with insults of bodily 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 amount of absorbent articles per package.

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.

<FIG> illustrate example cross-sectional views of absorbent articles within the scope of the present disclosure. <FIG> is an example cross-sectional view taken within a front waist region <NUM> of an absorbent article. <FIG> is an example cross-sectional view taken within a crotch region <NUM> of an absorbent article. <FIG> is an example cross-sectional view taken within a back waist region <NUM> of an absorbent article. In <FIG>, an outer cover material is element <NUM>, a liquid permeable topsheet is element <NUM>, opacity patches are elements <NUM>, a liquid impermeable backsheet is element <NUM>, an absorbent core is element <NUM>, with the core bag being element <NUM>, an absorbent material is element <NUM>, and a distribution material is element <NUM>. The distribution material <NUM> may comprise cross-linked cellulosic material and may be optional. An acquisition material is element <NUM>. A liquid permeable topsheet is element <NUM>. Barrier leg cuffs are elements <NUM>. Elastics in the barrier leg cuffs are elements <NUM>. Back ears are elements <NUM>. Fasteners on the back ears <NUM> are elements <NUM>. Construction glues and/or bonds between the various layers and/or components have been removed for clarity. Other cross-sectional configurations known to those of skill in the art are also within the scope of the present disclosure.

Webs or topsheets for absorbent articles or other consumer products are provided herein. The absorbent articles discussed herein may comprise the webs as a topsheet, an acquisition material, a distribution material, a secondary topsheet, a core cover, an outer cover nonwoven, a portion of an elastic belt, and/or other components, for example. The webs or topsheets discussed herein form a single layer web In some instances, the webs or topsheets may comprise wet-laid nonwoven materials, air-laid nonwoven materials, through-air bonded nonwoven materials, meltblown nonwoven materials, nano-fiber nonwoven materials, spunbond nonwoven materials, carded (staple fiber) nonwoven materials, spunlace nonwoven materials, or combinations of the same. The webs or topsheets may comprise synthetic and/or natural fibers. The natural fibers may comprise cotton, pulp, and/or bamboo, for example.

Referring to <FIG>, the webs or topsheets <NUM> comprises a continuous land area <NUM> or a plurality of discrete land areas. The webs or topsheets <NUM> also comprise a plurality of discrete zones of modified surface energy <NUM>. The discrete zones of modified surface energy <NUM> have a different surface energy than the continuous land area. The continuous land area is hydrophobic, and the discrete zones of modified surface energy are hydrophilic The discrete zones of modified surface energy may comprise or form increased permeability regions that acquire bodily exudates faster than the continuous land area. The discrete zones of modified surface energy <NUM> may comprise bonds or be formed by bonds in the webs or topsheets <NUM>. The bonds may be calendar or point bonds, overbonds, or other types of bonds, such as ultrasonic bonds.

Referring to <FIG>, the discrete zones of modified surface energy <NUM> may also be formed by bonds ruptured to form apertures or merely by aperturing, such as pin aperturing. As a result, perimeters of the apertures, partial perimeters of the apertures, and/or areas around the perimeters may comprise the discrete zones <NUM>. In some forms, the discrete zones of modified surface energy <NUM> are not formed by applying a topical surface energy modifying treatment or by printing a surface energy modifying agent or treatment. Further, in some forms, the discrete zones of modified surface energy do not comprise topical surface energy modifying treatments. The discrete zones of modified surface energy <NUM> may take on any suitable pattern, shape, and/or size. As an example, the discrete zones <NUM> may be uniform in size, shape, and/or spacing therebetween or non-uniform in size, shape, and/or spacing therebetween. The discrete zones <NUM> may be formed in patterns or arrays or may be uniform throughout a web or topsheet. Any suitable number of discrete zones <NUM> may be formed in a topsheet or web.

The webs or topsheets comprise a plurality of fibers. The fibers comprise (or be formed only by) bicomponent fibers Referring to <FIG>, an example side view of a bicomponent fiber <NUM> is illustrated. The bicomponent fiber <NUM> may comprise a spunbond bicomponent fiber, a carded bicomponent fibers, a micro-fiber bicomponent fiber, a nano-fiber bicomponent fiber, a meltblown bicomponent fiber, or a bicomponent fiber comprising one or more natural components or bio-sourced components, for example. The fibers may have a round or non-round cross-section. As used herein, the term "non-round fiber(s)" describes fibers having a non-round cross-section, and comprises "shaped fibers" and "capillary channel fibers. " Such fibers may be solid or hollow, and the fibers may be tri-lobal, delta-shaped, and may comprise fibers having capillary channels on their outer surfaces. The capillary channels may be of various cross-sectional shapes such as "U-shaped", "H-shaped", "C-shaped" and "V-shaped". The fibers may be round, hollow, or shaped, such as tri-lobal, ribbon, capillary channel fibers (e.g., 4DG). The bicomponent fibers may be any of the following types of bicomponent fibers, such as PP/PE, PET/PE, PET/coPET, or PLA/PE, for example. The bicomponent fibers may also comprise bio-sourced materials, natural material, or blends of the same.

The bicomponent fibers may have a concentric or eccentric core/sheath configuration, where at least a portion of a surface of the fibers comprises a lower melting component, for example. The bicomponent fibers may be blended with other fibers that are monocomponent fibers to form a topsheet or a web so that the topsheet or the web is formed at least partially by bicomponent fibers.

The bicomponent fibers may have a first component and a second component. At least some of, or all of, the first components (outer component) comprise a hydrophobic melt additive. At least some of, or all of, the second components (inner component) comprise a hydrophilic melt additive. Typically, the first component will surround the second component until heat, pressure, and/or energy is provided to the precursor web or topsheet. In such an instance, the second component may only be exposed in the discrete zones <NUM> thereby rendering the discrete zones hydrophilic and maintaining the continuous land area <NUM> hydrophobic or rendering the discrete zones to have a different hydrophilicity than the continuous land area.

Any suitable hydrophilic melt additives may be used in the bicomponent fibers to form the first or second components (depending on the desired configuration of the fibers). Examples include those available from Techmer PM, Clinton, Tennessee, USA sold under the trade name of Techmer PPM15560; TPM12713, PPM19913, PPM <NUM>, PPM19914, PPM112221 (for polypropylene), and/or PM19668, PM112222 (for polyethylene). Additional examples are available from Polyvel Inc. located in Hammonton, New Jersey, USA, sold under the trade name of Polyvel VW351 PP Wetting Agent (for polypropylene); from Goulston Technologies Inc. located in Monroe, North Carolina, USA sold under the trade name Hydrosorb <NUM>; as well as those hydrophilic additives disclosed in <CIT> and <CIT> and <CIT>.

Some polymers like PET may be made inherently hydrophilic by incorporation of hydrophilic comonomers into the polymer chain. Polylactic acid can be effectively rendered hydrophilic by using the melt additives such as Unithox <NUM> (with additional tempering), Pluronic F68, Pluronic F88, and Pluronic F108. This may be a further form of providing a hydrophilic second component in a bicomponent fiber.

Any suitable hydrophobic melt additives may be used in the bicomponent fibers to form the first or second components (depending on the desired configuration of the fibers). Some examples of hydrophobic melt additives are glycerol tristearate (GTS) and Erucamide. Other examples of hydrophobic melt additives may comprise fatty acids and fatty acid derivatives. The fatty acids may originate from vegetable, animal, and/or synthetic sources. Some fatty acids may range from a C8 fatty acid to a C30 fatty acid, or from a C12 fatty acid to a C22 fatty acid. In other forms, a substantially saturated fatty acid may be used, particularly when saturation arises as a result of hydrogenation of fatty acid precursor. Examples of fatty acid derivatives include fatty alcohols, fatty acid esters, and fatty acid amides. Suitable fatty alcohols (R-OH) include those derived from C12-C28 fatty acids.

Without being bound by theory, it is believed that having a hydrophobic resin or melt additive in a sheath or sea of a bicomponent fiber may help to retard the migration of a hydrophilic resin or melt additive in a core or islands of the bicomponent fiber.

Further details regarding the hydrophilic and hydrophobic melt additives are disclosed in <CIT>.

<FIG> is an example cross-sectional view of the fiber <NUM> taken about line <NUM>-<NUM> of <FIG> illustrating a concentric core/sheath bicomponent fiber. The sheath is formed by a first component <NUM> and the core is formed by a second component <NUM>. The first component <NUM> comprises a hydrophobic melt additive and the second component <NUM> comprises a hydrophilic melt additive.

<FIG> is an example cross-sectional view of the fiber <NUM> taken about line <NUM>-<NUM> of <FIG> illustrating an islands-in-the-sea bicomponent fiber which is not within the scope of the claimed invention. The sea may be formed by a first component <NUM> and the islands may be formed by a second component <NUM>. The islands may take on any suitable shape, such as circular, elliptical, and/or ovate, for example. The first component <NUM> may comprise a hydrophobic resin and/or a hydrophobic melt additive and the second component <NUM> may comprise a hydrophilic resin and/or a hydrophilic melt additive.

<FIG> is an example cross-sectional view of the concentric core/sheath bicomponent fiber <NUM> of <FIG> in a discrete zone of modified surface energy (i.e., after heat and/or energy has been applied to the fiber). The sheath/first component <NUM> comprising hydrophobic melt additive may be partially or fully moved or melted away due to the energy/heat. As a result, the core/second component <NUM> comprising the hydrophilic melt additive may be at least partially exposed, thereby rendering the discrete zone of modified surface energy hydrophilic or at least partially hydrophilic. In the continuous land area <NUM>, where heat and/or energy are not applied to the web or topsheet, the sheath/first component <NUM> may not expose the core/second component <NUM>, thereby maintaining the fibers in the continuous land area hydrophobic.

As an alternative to the sheath/sea/first components herein being partially or fully moved or melted away in a discrete zone of modified surface energy, the first and second components may be fused and/or blended together in the discrete zones when heat and/or energy is applied, thereby rendering the discrete zone to have a surface energy that is a blend of the first and second components. Stated another way, the discrete zones may have a surface energy intermediate a surface energy of the first component and a surface energy of the second component. This is not the result of the melt additive(s) spontaneously blooming, but occurs after any spontaneous blooming.

<FIG> is an example cross-sectional view of the islands-in-the-sea bicomponent fiber <NUM> (not within the scope of the claimed invention) of <FIG> in a discrete zone of modified surface energy (i.e., after heat and/or energy has been applied to the fiber). The sea/first component <NUM> comprising the hydrophobic resin and/or hydrophobic melt additive may be partially or fully melted away due to the energy/heat. As a result, the islands/second component <NUM> comprising the hydrophilic resin and/or hydrophilic melt additive may be at least partially exposed, thereby rendering the discrete zone of modified surface energy hydrophilic or at least partially hydrophilic. In the continuous land area <NUM>, where heat and/or energy are not applied to the web or topsheet, the sea/first component <NUM> may not expose the islands/second component <NUM>, thereby maintaining the fibers in the continuous land area hydrophobic.

<FIG> is an example cross-sectional view of the fiber <NUM> taken about line <NUM>-<NUM> of <FIG> illustrating an eccentric core/sheath bicomponent fiber. The sheath is formed by a first component <NUM> and the core is formed by a second component <NUM>. The first component <NUM> may comprises a hydrophobic melt additive and the second component <NUM> may comprises a hydrophilic melt additive. In order to expose the hydrophilic second component or core of the bicomponent fiber only by heat, an eccentric core/sheath bicomponent geometry may be advantageous in that it may enable the first component or sheath to easily flow away on one side (since it is thinner), further aided by the incompatibility of core and sheath.

Different measures may be taken to further increase the flowing tendency of the sheath of a bicomponent fiber. In through-air bonding, for example, the sheath is typically a polymer of lower melting point than the core (e.g., a PE in the sheath versus PP or PET in the core). The use of grades of polymers with lower molecular weights for the sheath may help to further increase the flow rate of the sheath.

<FIG> is an example cross-sectional view of the eccentric core/sheath bicomponent fiber <NUM> of <FIG> in a discrete zone of modified surface energy (i.e., after heat and/or energy has been applied to the fiber). The sheath/first component <NUM> comprising the hydrophobic melt additive may be partially or fully melted away due to the energy and/or heat. As a result, the core/second component <NUM> comprising the hydrophilic melt additive may be at least partially exposed, thereby rendering the discrete zone of modified surface energy hydrophilic or at least partially hydrophilic. In the continuous land area <NUM>, where heat and/or energy are not applied to the web or topsheet, the sheath/first component <NUM> may not expose the core/second component <NUM>, thereby maintaining the fibers in the continuous land area hydrophobic. Eccentric core/sheath bicomponent fibers may be desired for the present disclosure in that the core/second component <NUM> is already proximate to an outer surface of the fiber prior to heat and/or energy being applied to the fibers in the discrete zones. As a result, it may require less heat and/or energy to expose the core/second component <NUM> of an eccentric fiber and render the fiber at least partially hydrophilic on its outer surface.

<FIG> is a microscope image of some fibers of a continuous land area <NUM> of a web or topsheet comprising concentric core/sheath bicomponent fibers after having droplets of water applied thereto, according to the Contact Angle Test herein. <FIG> is a further magnified view of the fibers of the continuous land area <NUM> of <FIG>. The sheath/first component <NUM> (see <FIG>) comprises a hydrophobic melt additive. The core/second component <NUM> (see <FIG>) comprises a hydrophilic melt additive. In the continuous land area <NUM>, the core/second component <NUM> is not exposed to maintain the continuous land area hydrophobic. The measured contact angle with water in the sample illustrated in <FIG> was <NUM> degrees +/- <NUM> degrees, according to the Contact Angle Test herein. Therefore, the bicomponent fibers in the continuous land area maintain their hydrophobic character.

<FIG> is a microscope image of some fibers of a calendar bond of a discrete zone of modified surface energy comprising concentric core/sheath bicomponent fibers after having droplets of water applied thereto, according to the Contact Angle Test herein. <FIG> is a further magnified view of the fibers of the calendar bond of <FIG>. The sheath/first component <NUM> (see <FIG>) comprises a hydrophobic melt additive. The core/second component <NUM> (see <FIG>) comprises a hydrophilic melt additive. In the overbond, the core/second component <NUM> is exposed to render the overbond (discrete zone) hydrophilic. The measured contact angle in the sample illustrated in <FIG> was <NUM> degrees +/- <NUM> degrees, according to the Contract Angle Test herein. Therefore, the bicomponent fibers in the overbond (or discrete zone of modified surface energy) are rendered hydrophilic.

<FIG> is a microscope image of some fibers of a portion of an overbond. The overbond may be considered a discrete zone of modified surface energy. The overbond has droplets of water applied thereto, according to the Contact Angle Test therein. <FIG> is a further magnified view of the fibers of the portion of the overbond of <FIG>. As can be seen from the water droplets, the bicomponent fibers in overbond are rendered hydrophilic since the contact angle between the fibers and the droplets of the water are less than <NUM> degrees. On information and belief, the contact angle on the fibers of the overbond may be lower than the fibers of the continuous land area of <FIG> and lower than the contact angle of the fibers in the calendar bond of <FIG>.

<FIG> is a microscope image of melt rims <NUM> around apertures <NUM>, wherein the apertures <NUM> were created by cross-directionally stretching an overbond. The melt rims <NUM> may have the same or similar contact angle as the overbonds of <FIG>.

<FIG> are images of a spunbond web with a basis weight of <NUM> gsm. The spunbond web was produced using approximately <NUM> micron diameter sheath/core bicomponent fibers. The sheath was polyethylene (Dow Aspun™ 6850A) and a hydrophobic masterbatch comprising glyceryl tristearate. The core was polypropylene (Exxon Mobile PP3155), TiO<NUM>, and a hydrophilic masterbatch (PPM15560 from Techmer). Overbonds were created by running the nonwoven webs between a heated anvil roll and a pattern roll at 900ft/min at conditions sufficient to generate flow in the polymers. Contact angles were measured according to the Contact Angle Test herein.

<FIG> is an example of a portion of topsheet or web <NUM> having a continuous land area <NUM> and discrete zones of modified surface energy <NUM>. The topsheet or web <NUM> has a pattern of what is considered a uniform and homogeneous pattern of apertures (intended to be uniform and homogenous). Each of the apertures <NUM> has a perimeter. The discrete zones of modified surface energy <NUM> are formed in and/or proximate to at least some of, or all of, the aperture perimeters. The discrete zones may also be formed partially around perimeters of the apertures.

<FIG> is an example of a portion of a topsheet or web <NUM> having a continuous land area <NUM> and discrete zones of modified surface energy <NUM>. The topsheet or web <NUM> has a pattern of what is considered non-uniform and nonhomogeneous apertures <NUM>. Each of the apertures <NUM> has a perimeter. The discrete zones of modified surface energy <NUM> are formed in and/or proximate to at least some of, or all of, the aperture perimeters. The discrete zones may also be formed partially around perimeters of the apertures <NUM>.

<FIG> is another example of a portion of a topsheet or web <NUM> having a continuous land area <NUM> and discrete zones of modified surface energy <NUM>. The topsheet or web <NUM> has a pattern of what is considered non-uniform and nonhomogeneous apertures <NUM>. Each of the apertures <NUM> has a perimeter. The discrete zones of modified surface energy <NUM> are formed in and/or proximate to at least some of, or all of, the aperture perimeters. The discrete zones may also be formed partially around perimeters of the apertures <NUM>.

<FIG> show some example aperture patterns, but the present disclosure is not limited to such patterns and may have any suitable patterns tailored for a certain intended purpose.

The basis weight of webs or topsheets of the present disclosure may vary according to the intended purpose of the webs or topsheets. The basis weight of the webs or topsheets may be in the range of about <NUM> gsm (grams per square meter) 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 10gsm to about <NUM> gsm, about <NUM> gsm to about <NUM> gsm, or about <NUM> gsm to about <NUM> gsm, specifically reciting all <NUM> gsm increments within the specified ranges and all ranges formed therein or thereby.

The webs or topsheets discussed herein may have the same color or different colors than other webs or layers in an absorbent article or other consumer product. In some instances, a web or topsheet may be a first, non-white color, and a second material may be white or may be a second non-white color. As an example, a web or topsheet may be white and the second material may be teal, or vice versa. As another example, a web or topsheet may be teal and the second nonwoven material may be blue, or vice versa.

<FIG> illustrates a top view photograph of a portion of a web or topsheet comprising calendar or point bonds that form discrete zones of modified surface energy <NUM>. The web or topsheet <NUM> of <FIG> also illustrates a continuous land area <NUM>. The web or topsheet comprises bicomponent fibers having a first component and a second component as discussed herein. <FIG> is a cross-sectional schematic illustration taken about line <NUM>-<NUM> of <FIG>. <FIG> illustrates a calendar or point bond that forms a discrete zone of modified surface energy <NUM> surrounded by unbonded fibers <NUM> in the continuous land area <NUM>. The calendar or point bonds are essentially highly densified regions within the web or topsheet. These calendar or point bonds typically have uniform sizes, shapes, and are uniformly spaced relative to each other. The calendar or point bonds may be used during the nonwoven web manufacturing process to join some of the fibers <NUM> together to form the nonwoven webs and provide them with integrity. Typically, these calendar or point bonds are created by conveying the bicomponent fibers of the present disclosure through a nip between a calendar roll having plurality of nubs (that create the bonds) and an anvil roll, as is generally known in the art.

The apertured webs or topsheets of the present disclosure may be made generally by using the process generally described in <CIT> and <CIT>. This process is described in further detail below. The apertured webs or topsheets may also be made by hydroforming carded webs, laser cutting, punching with a patterned roll, pin-aperturing, or other suitable aperturing methods.

Referring to <FIG> there is schematically illustrated at <NUM> one process for forming apertured webs or topsheets. First, a precursor material <NUM> is supplied as the starting material. The precursor material <NUM> may be supplied as roll stock. The precursor material <NUM> a single layer web, such as a single layer spunbond on continuous fiber web, having bicomponent fibers with a first component comprising a hydrophobic melt additive and with a second component comprising a hydrophilic melt additive.

The precursor material <NUM> may be unwound from a supply roll <NUM> and travel in a direction indicated by the arrow associated therewith as the supply roll <NUM> rotates in the direction indicated by the arrow associated therewith. The precursor material <NUM> passes through a nip <NUM> of a weakening roller (or overbonding) arrangement <NUM> formed by rollers <NUM> and <NUM>, thereby forming a weakened or overbonded precursor material. The weakened or overbonded precursor material <NUM> has a pattern of overbonds, or densified and weakened areas, after passing through the nip <NUM>. At least some of, or all of, these overbonds may be used to form apertures in the precursor material <NUM>. As such, at least some of the overbonds may correlate generally to the patterns of apertures created in the precursor material <NUM>. The overbonds may be uniform and homogenous or may have a pattern that is non-uniform and/or nonhomogeneous. In other instances, the overbonds may not be ruptured into apertures and the overbonds themselves may form the discrete zones of modified surface energy in a web or topsheet.

Referring to <FIG>, the precursor material weakening roller arrangement <NUM> may comprises a calendar roller <NUM> and a smooth anvil roller <NUM>. One or both of the patterned calendar roller <NUM> and the smooth anvil roller <NUM> may be heated and the pressure between the two rollers may be adjusted by known techniques to provide the desired temperature, if any, and pressure to concurrently weaken and melt-stabilize (i.e., overbond) the precursor material <NUM> at a plurality of locations <NUM>. The temperature and/or pressured should be sufficient to render the discrete zones of modified surface energy (i.e., the bonded areas) hydrophilic or hydrophobic as desired. After the precursor material <NUM> passes through the weakening roller arrangement <NUM>, the precursor material <NUM> may be stretched in the cross-machine direction ("CD") or generally in the CD, by a cross-machine directional tensioning force to at least partially, or fully, rupture the plurality of weakened, melt stabilized locations <NUM>, thereby creating a plurality of at least partially formed apertures in the precursor material <NUM> coincident with the plurality of weakened, melt stabilized locations <NUM>. In the context of apertures, the discrete zones of modified surface energy may be formed at least partially around, or fully around, perimeters of the apertures and/or in areas proximate to the apertures (e.g., areas of the overbonds remaining after apertures are formed).

The calendar roller <NUM> is configured to have a cylindrical surface <NUM>, and a plurality of protuberances <NUM> which extend radially outwardly from the cylindrical surface <NUM>. The protuberances <NUM> are illustrated as a simplified example of a calendar roller <NUM>, but more detailed patterned calendar rollers can be used to produce patterned apertured webs, such as that illustrated in <FIG> and <FIG>, for example. The protuberances <NUM> may be disposed in a predetermined pattern with each of the protuberances <NUM> being configured and disposed to precipitate a weakened, melt-stabilized location in the precursor material <NUM> to affect a predetermined pattern of weakened, melt-stabilized locations <NUM> in the precursor material <NUM>. The protuberances <NUM> may have a one-to-one correspondence to the pattern of melt stabilized locations in the precursor material <NUM>.

The protuberances <NUM> may have distal end surfaces <NUM>. The anvil roller <NUM> may be a smooth surfaced, circular cylinder of steel, rubber, and/or other material. The anvil roller <NUM> and the patterned calendar roller <NUM> may be switched in position (i.e., anvil on top) and achieve the same result.

From the weakening roller arrangement <NUM>, the material <NUM> passes through a nip <NUM> formed by an incremental stretching system <NUM> employing opposed pressure applicators having three-dimensional surfaces which at least to a degree may be complementary to one another.

Referring now to <FIG>, there is shown a fragmentary enlarged view of the incremental stretching system <NUM> comprising two incremental stretching rollers <NUM> and <NUM>. The incremental stretching roller <NUM> may comprise a plurality of teeth <NUM> and corresponding grooves <NUM> which may extend about the entire circumference of roller <NUM>. The incremental stretching roller <NUM> may comprise a plurality of teeth <NUM> and a plurality of corresponding grooves <NUM>. The teeth <NUM> on the roller <NUM> may intermesh with or engage the grooves <NUM> on the roller <NUM> while the teeth <NUM> on the roller <NUM> may intermesh with or engage the grooves <NUM> on the roller <NUM>. The spacing and/or pitch of the teeth <NUM> and/or the grooves <NUM> may match the pitch and/or spacing of the plurality of weakened, melt stabilized locations <NUM> in the precursor material <NUM> or may be smaller or larger. As the precursor material <NUM> having weakened, melt-stabilized locations <NUM> passes through the incremental stretching system <NUM>, the precursor material <NUM> is subjected to tensioning in the CD causing the material <NUM> to be extended (or activated) in the CD, or generally in the CD. Additionally, the material <NUM> may be tensioned in the MD, or generally in the MD. The CD tensioning force placed on the material <NUM> may be adjusted such that it causes the weakened, melt-stabilized locations <NUM> to at least partially, or fully, rupture thereby creating a plurality of partially formed, or formed apertures <NUM> coincident with the weakened melt-stabilized locations <NUM> in the material <NUM>. However, the bonds of the material <NUM> (in the non-overbonded areas) are strong enough such that they do not rupture during tensioning, thereby maintaining the material <NUM> in a coherent condition even as the weakened, melt-stabilized locations rupture.

Referring to <FIG>, a more detailed view of the teeth <NUM> and <NUM> and the grooves <NUM> and <NUM> on the rollers <NUM> and <NUM> is illustrated. This is known as a "ring rolling" process. The term "pitch" refers to the distance between the apexes of adjacent teeth. The pitch may be between about <NUM> inches to about <NUM> inches or may be between about <NUM> inches and about <NUM> inches, specifically reciting all <NUM> inch increments within the above-specified ranges and all ranges formed therein or thereby. The height (or depth) of the teeth is measured from the base of the tooth to the apex of the tooth, and may or may not be equal for all teeth. The height of the teeth may be between about <NUM> inches and about <NUM> inches or may be between about <NUM> inches and about <NUM> inches, specifically reciting all <NUM> inch increments within the above-specified ranges and all ranges formed therein or thereby. The teeth <NUM> in one roll may be offset by about one-half of the pitch from the teeth <NUM> in the other roll, such that the teeth of one roll (e.g., teeth <NUM>) mesh in the valley (e.g., groove <NUM>) between teeth in the mating roll. The offset permits intermeshing of the two rolls when the rolls are "engaged" or in an intermeshing, operative position relative to one another. The teeth of the respective rolls may only be partially intermeshing in some instances. The degree to which the teeth on the opposing rolls intermesh is referred to herein as the "depth of engagement" or "DOE" of the teeth. The DOE may be constant or not constant. As shown in <FIG>, the DOE, indicated as "E", is the distance between a position designated by plane P1 where the apexes of the teeth on the respective rolls are in the same plane (<NUM>% engagement) to a position designated by plane P2 where the apexes of the teeth of one roll extend inward beyond the plane P1 toward the groove on the opposing roll. The optimum or effective DOE for particular web may be dependent upon the height and the pitch of the teeth and/or the structure of the material. Some example DOEs may be in the range of about <NUM> inches to about <NUM> inches or about <NUM> inches to about <NUM> inches.

As the material <NUM> having the weakened, melt-stabilized locations <NUM> passes through the incremental web stretching apparatus <NUM>, the material <NUM> is subjected to tensioning in the cross machine direction, or substantially in the cross machine direction (i.e., +/- <NUM> degrees of the cross machine direction) thereby causing the nonwoven web <NUM> to be extended in the cross machine direction. The tensioning force placed on the material <NUM> may be adjusted by varying the pitch, DOE, or teeth size, such that the incremental stretching is sufficient to cause the weakened, melt-stabilized locations <NUM> to at least partially, or fully rupture, thereby creating, or at least partially creating, a plurality of apertures <NUM> coincident with the weakened, melt-stabilized locations <NUM> in the material <NUM>. At least some of, or all of, the apertures may comprise a melt lip at least partially surrounding a perimeter of the apertures. The melt lip may be formed by portions of the overbonds.

The material <NUM> comprises bicomponent fibers having a first component and a second component. The first component comprises a hydrophobic melt additive. The second component comprises a hydrophilic melt additive. The weakened, melt-stabilized locations <NUM> and the resulting aperture rims or perimeters of apertures (including the melt lips) may be at least partially hydrophilic owing to the heat and/or energy provided to the material <NUM> during overbonding. The heat and/or energy may at least partially move and/or melt the first component and at least partially expose the second component. As such, the second component of the fibers of the material <NUM> is at least partially exposed to render the weakened, melt-stabilized locations <NUM> or perimeters of apertures at least partially hydrophilic. The continuous land area may remain hydrophobic as the second component is not exposed therein. As mentioned above, instead of removing or melting away the first component, the first and second components may be blended in the weakened, melt-stabilized locations <NUM> to have a surface energy intermediate a surface energy of the first component and a surface energy of the second component.

Other details regarding the overbonding and ring rolling process to create apertures are disclosed in <CIT>.

Referring to <FIG>, another process of creating apertures and/or three-dimensional elements in a topsheet or web is disclosed. In this process, a precursor material <NUM> is conveyed through a nip <NUM> between a first roll <NUM> and a second roll <NUM> to create an apertured and three-dimensional web or topsheet <NUM>. The precursor material <NUM> may be wrapped at least partially around the first roll <NUM> or the second roll <NUM> to provide better three-dimensional element formation and/or aperture formation. The first roll <NUM> may rotate about a first rotational axis <NUM> in the direction shown by the arrow and the second roll <NUM> may rotate about a second rotational axis <NUM> in the direction shown by the arrow. The first roll <NUM> may have a first radial outer surface <NUM> and the second roll <NUM> may have a second radial outer surface <NUM>.

<FIG> is an example engaged, cross-sectional view of portions of the first and second rolls <NUM> and <NUM> of <FIG> in the nip <NUM>. The first roll <NUM> may comprise a first plurality of projections <NUM> each comprising a distal portion <NUM> for creating apertures and a first plurality of recesses <NUM> defined therein. The second roll <NUM> may comprise a second plurality of projections <NUM> for creating three-dimensional elements in the precursor material <NUM>. The second roll <NUM> may comprise a second plurality of recesses <NUM> defined therein. The first plurality of projections <NUM> may at least partially engage the second plurality of recesses <NUM> in the nip <NUM>. The second plurality of projections <NUM> may at least partially engage the first plurality of recesses <NUM> in the nip <NUM>. The distal portions <NUM> of the first plurality of projections <NUM> may engage shoulders <NUM> on the second plurality of projections <NUM> and compress portions of the precursor material <NUM> positioned therebetween to form compressed areas in the precursor material <NUM> around apertures.

The precursor material <NUM> comprises fibers that are bicomponent fibers having a first component and a second component. The first component comprises hydrophobic melt additive. The second component comprises a hydrophilic melt additive. The compressed areas may have at least some of the hydrophilic second component of the bicomponent fibers exposed due to the heat and/or energy created in the precursor material <NUM> intermediate the distal portions <NUM> and the shoulders <NUM>. This may render the compressed areas hydrophilic or at least partially hydrophilic. The compressed areas may form the discrete zones of modified surface energy discussed herein, with the three-dimensional elements forming the continuous land area that is hydrophobic.

<FIG> is another example engaged, cross-sectional view of the first and second rolls <NUM> and <NUM> of <FIG> in the nip <NUM>. The primary difference between <FIG> and <FIG> is the process only creates apertures in the precursor material and not three-dimensional elements. Compressed areas are still formed intermediate the shoulders <NUM> and the distal portions <NUM>.

Further details regarding the process illustrated in <FIG> are described in <CIT>.

The discrete zones of modified surface energy may also be created in a web or topsheet using the process described in <CIT>.

The discrete zones of modified surface energy may also be created in a web or topsheet using a standard embossing process, a heated embossing process, and/or a bonding process, such as a calendar or through-air bonding process or other suitable process of inducing heat, pressure, and/or energy. The discrete zones of modified surface energy may also be formed by laser ablation.

The present disclosure is directed, in part to a method of manufacturing a nonwoven web or topsheet comprising discrete zones of modified surface energy. The method comprises providing a web comprising bicomponent fibers, wherein at least some of the bicomponent fibers each comprise a first component and a second component. The first component comprises a hydrophobic melt additive. The second component comprises a hydrophilic melt additive. The method comprises providing a continuous land area in the web. In the continuous land area, the first component surrounds the second component in the fibers and the second component is not exposed to maintain the continuous land area hydrophobic (or hydrophilic depending on what component is hydrophobic/hydrophilic). The method comprises applying heat or energy to the web to create bonds or apertures in the web to form the discrete zones of modified surface energy within the continuous land area. The application of heat or energy step occurs after any spontaneous blooming of the hydrophilic melt additive and/or the hydrophobic melt additive. In the discrete zones of modified surface energy, the second component is at least partially exposed to render the discrete zones of modified surface energy at least partially hydrophilic (or hydrophobic depending on what component is hydrophobic/hydrophilic). The method may comprise applying heat or energy to form only discrete bonds or applying heat or energy to form only apertures.

The at least some of the bicomponent fibers are core/sheath type bicomponent fibers. The first component forms the sheath and the second component forms the core. These core/sheath type bicomponent fibers may be concentric or eccentric.

The method may comprise conveying the web in a machine direction. The applying heat or energy step may comprise forming overbonds in the web. The method may comprise stretching the web substantially in a cross-machine direction to at least partially rupture at least some of the overbonds and at least partially form apertures and forming the discrete zones of modified surface energy at least partially on perimeters of the apertures.

Alternatively, the applying heat or energy step may comprise pin aperturing the web to form apertures. The discrete zones of modified surface energy may be formed on perimeters of the apertures and/or in areas adjacent to the perimeters of the apertures.

The nonwoven topsheet is formed of a single layer and may be free of topical, surface energy modifying, treatments or printed, surface energy modifying, treatments.

The present disclosure is directed, in part, to a method of manufacturing a single layer, nonwoven topsheet comprising discrete zones of modified surface energy. The method comprises providing a web comprising bicomponent fibers. At least some of the bicomponent fibers each comprise a first component and a second component. The first component comprises a hydrophobic melt additive. The second component comprises a hydrophilic melt additive. The method may comprise conveying the web in a machine direction and providing a continuous land area in the web. In the continuous land area, the first component surrounds the second component and the second component is not be-exposed to maintain the continuous land area hydrophobic. The method may comprise applying heat or energy to the web to create discrete overbonds in the web within the continuous land area and stretching the web substantially in a cross-machine direction to at least partially rupture at least some of the overbonds in the web and at least partially form apertures. The application of heat or energy step may occurs after any spontaneous blooming of the hydrophilic melt additive and/or the hydrophobic melt additive. The discrete zones of modified surface energy may be at least partially formed on perimeters of the apertures and/or in areas proximate to the perimeters of the apertures. The second component may be at least partially exposed in the discrete zones of modified surface energy to render the perimeters of the apertures at least partially hydrophilic. The at least some of the bicomponent fibers are core/sheath type bicomponent fibers. The first component forms the sheath and the second components forms he core.

The discrete zones of modified surface energy herein are not formed by through-air bonding, but may be formed on a through-air bonded base substrate.

The hydrophilic melt additives disclosed as the second component of the bicomponent fibers herein may spontaneously bloom until they reach some equilibrium state. This spontaneous blooming, however, may be contained by the hydrophobic melt additives disclosed herein. As such, the hydrophilic melt additive spontaneously blooming is not the process by which the discrete zones of modified surface energy are formed. Instead, these discrete zones of modified surface energy are formed after any spontaneous blooming has occurred. Stated another way, any spontaneous blooming of the hydrophilic melt additive is separated in time from creating or exposing of the discrete zones of modified surface energy. The hydrophobic melt additives disclosed as the first component of the bicomponent fibers may also spontaneously bloom until they reach some equilibrium state.

Overbonds were created by running a nonwoven web between a heated anvil roll and pattern roll at 900ft/min at conditions sufficient to generate flow of the polymers in the nonwoven web. (See process and related description of <FIG>).

Overbonds were created by running the nonwoven web between an ultrasonic horn and patterned plate under conditions sufficient to generate flow of the polymers in the nonwoven web.

The overbonded webs of C1, C2, and the Present Disclosure were hand cranked through a <NUM>" pitch ring roll, set to a depth of engagement ("E" of <FIG>) of <NUM>" to create the apertures. (See <FIG> and <FIG> and related description, although this example was done by hand, the process is the same. ) The aperture patterns of the webs are generally represented in <FIG>.

Images of the apertured webs (C1, C2, and the Web of the Present Disclosure) were collected by taking images of the webs over a black background using a Nikon D7100 equipped with an AF Micro Nikkor <NUM>, <NUM>:<NUM>. The following ImageJ macro was used to measure the Aperture Area and % Open Area after setting the scale from an image of a ruler. run("Make Binary");
run("Convert to Mask");
run("Fill Holes");
run("Analyze Particles. ", "size=<NUM>-Infinity display exclude include summarize add
in_situ");
roiManager("Show All with labels");
roiManager("Show All");
run("Flatten").

Present Disclosure Example = <NUM> gsm spunbond web having approximately <NUM> micron diameter sheath/core bicomponent fibers. The sheath was polyethylene (Dow AspunTM 6850A) and a hydrophobic masterbatch comprising glyceryl tristearate. The core was polypropylene (Exxon Mobile PP3155), TiO2, and a hydrophilic masterbatch (PPM15560 from Techmer).

The methods to determine the <NUM>st Gush Acquisition Speed, Rewet, and the Stain Intensity (Chroma) can be found in <CIT>; <CIT>; and <CIT>.

The nonwoven webs or topsheets of the present disclosure have a first gush acquisition speed much faster than a single layer hydrophobic web (C1). The nonwoven webs or topsheets of the present disclosure have a lower rewet than a single layer hydrophilic web (C2). The nonwoven webs or topsheets of the present disclosure have the lowest stain intensity (i.e., best masking) than both the hydrophilic web (C1) and the hydrophobic web (C2).

A rectangular specimen measuring <NUM> x <NUM> is cut from the topsheet of a disposable absorbent article taking care not to touch the surface of the specimen or to disturb the structure of the material. The specimen coincides with a region of interest of the topsheet of the absorbent article, with the length of the specimen (<NUM>) aligned with a central longitudinal axis of the absorbent article. The specimen is handled gently by the edges using forceps and is mounted flat with the skin-facing side up on an SEM specimen holder using double-sided tape. The specimen is sprayed with a fine mist of water droplets generated using a small hobby air-brush apparatus. The water used to generate the droplets is distilled deionized water with a resistivity of at least <NUM> MΩ-cm. The airbrush is adjusted so that the droplets each have a volume of about <NUM> pL. Approximately <NUM> of water droplets are evenly and gently deposited onto the specimen. Immediately after applying the water droplets, the mounted specimen is frozen by plunging it into liquid nitrogen. After freezing, the sample is transferred to a Cryo-SEM prep chamber at -<NUM>, coated with Au/Pd, and transferred into Cryo-SEM chamber at -<NUM>. A Hitachi S-<NUM> Cry-SEM or equivalent instrument is used to obtain high-resolution images of the droplets on the fibers. Droplets are randomly selected, though a droplet is suitable to be imaged only if it is oriented in the microscope such that the projection of the droplet extending from the fiber surface is approximately maximized. This is further discussed with regard to <FIG>. The contact angle between the droplet and the fiber is determined directly from the images taken as is shown via lines 3700A, 3700B, 3800A, 3800B, 3900A, 3900B, 4000A, and 4000B. Twenty separate droplets are imaged from which forty contact angle measurements are performed (one on each side of each imaged droplet), and the arithmetic average of these forty contact angle measurements is calculated and reported as the contact angle for that specimen.

Claim 1:
An absorbent article (<NUM>) comprising:
a nonwoven topsheet;
a backsheet (<NUM>); and
an absorbent core (<NUM>) positioned at least partially intermediate the topsheet (<NUM>) and the backsheet (<NUM>);
wherein the nonwoven topsheet (<NUM>) comprises:
a plurality of bicomponent fibers forming the nonwoven topsheet (<NUM>), at least some of the bicomponent fibers each comprise a first, outer component and a second, inner component (<NUM>, <NUM>), wherein the first component (<NUM>) comprises a hydrophobic melt additive, and wherein the second component (<NUM>) comprises a hydrophilic melt additive;
a continuous land area (<NUM>) comprising the bicomponent fibers; and
discrete zones of modified surface energy (<NUM>) comprising the bicomponent fibers, wherein at least a majority of the discrete zones of modified surface energy (<NUM>) are surrounded by the continuous land area (<NUM>);
wherein, in the continuous land area, the second component (<NUM>) is not exposed to maintain the continuous land area (<NUM>) hydrophobic; and
wherein, in at least some of the discrete zones of modified surface energy (<NUM>), the second component (<NUM>) is at least partially exposed to render the discrete zones of modified surface energy (<NUM>) hydrophilic; and
wherein the nonwoven topsheet (<NUM>) is formed of only a single layer; and
(i) wherein the discrete zones of modified surface energy (<NUM>) comprise bonds, or
(ii) wherein the discrete zones of modified surface energy (<NUM>) comprise perimeter portions at least partially surrounding apertures (<NUM>) in the topsheet (<NUM>).