Patent Description:
A variety of disposable absorbent articles have been relied on by consumers to handle or manage body exudates. These consumers may include babies, toddlers, children, teenagers, adults, and elderly persons. Thus, it is clear that the types of fluids or body exudates managed by such articles may vary as well to include urine, feces, menses, and other discharges. Typically, in the case of adults, the articles take the form of sanitary napkins, adult incontinence pads, and adult incontinence diapers or undergarments. One of the primary drivers of the desirability of these products to wearers is to give them assurance that when they experience incontinence, the occurrence of such will go unnoticed by others and even more ideally by the wearers.

Some manufacturers utilize visual signals to communicate to the wearer of the extent of the absorbent layers of the article. These visual signals can be particularly useful, especially when the absorbent article in question is relatively thin. Visual signals can help alleviate a wearer's anxiety regarding the threat of leakage from the article.

However, providing visual signals to communicate the extent of the absorbent layers can be problematic. The absorbent layers are generally disposed inboard of a periphery of the disposable absorbent article. This ensures that there is minimal leakage from the absorbent layers outside of the periphery of the article. That said, due to web tracking issues, printing on the absorbent layers generally means that the print signal can be disposed several centimeters inboard of the periphery both longitudinally and laterally. And, while printing on the topsheet can allow for a longer and possibly wider signal, printing on the topsheet can create a risk of ink bleeding onto a wearer's skin.

<CIT> is concerned with hygiene articles, such as feminine pads, for collecting bodily fluid. The articles include a be substantially white central fluid acquisition zone and two visually discernible lateral zones situated on opposite sides of the central zone. The lateral zones are formed by a nonwoven material including a colored pigment.

<CIT> relates to an absorbent personal care article having a longitudinal centerline and a transverse centerline and including a pair of opposed wings extending along the longitudinal sides of the article. The article further has two protective strips attached to the sides of the article and extending laterally outboard of the article and the edges of the wearer's undergarment to provide additional protection against leakage.

<CIT> discloses an absorbent hygiene article for placement in underwear. The topsheet is of a translucent material and is provided with a colored pattern defining at least one background region and at least one colored region having a first inherent color. The topsheet-facing side of the backsheet has a second color; and the background region located in an inner area has a higher L *-value than the background region located in the edge area.

<CIT> relates to absorbent articles, such as tampons and sanitary napkins, comprising one or more graphical elements. The graphical elements highlight the functional area of the absorbent article.

Based on the foregoing, there is a need to provide an absorbent article with a more dimensionally robust visual signal - one that communicates a more accurate account of the extent of the absorbent layers.

Described herein are disposable absorbent articles that assurance to users regarding their absorbent capacity. The absorbent articles described herein comprise a visual signal having a length which is a large percentage of the overall length of the absorbent article.

Disposable absorbent articles constructed in accordance with the present disclosure have a longitudinal centerline and a lateral centerline generally perpendicular to the longitudinal centerline, first and second side edges and first and second end edges disposed at a first end and a second end of the absorbent article, respectively. The absorbent article further comprises a topsheet; a backsheet; an absorbent system disposed between the topsheet and the backsheet; and a visual signal visible from a wearer-facing surface. And, the visual signal of the absorbent articles of the present disclosure have a length wherein a difference between a length of the disposable absorbent article and the length of the visual signal is less than <NUM>. The absorbent articles exhibit a performance factor of between <NUM> and <NUM>. The performance factor is calculated by dividing the difference between the article length and visual signal length by the measured caliper.

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as forming the present invention, it is believed that the invention will be better understood from the following description which is taken in conjunction.

The disposable absorbent articles, particularly incontinence pads or pants, of the present invention can provide flexibility to allow for an improved and comfortable fit which is less susceptible to bunching during use. In particular, it is envisioned that the articles of the present disclosure exhibit heightened structural resiliency from the proposed configuration and orientation of the layers contained therein. For the purposes of this disclosure, reference to an incontinence pad, disposable absorbent article, or absorbent article will be used. However, the present invention may be applied to a plurality of absorbent articles including, but not limited to, sanitary napkins, pantiliners, menstrual pads, diapers, training pants, adult incontinence pants, etc..

An "elastic," "elastomer" or "elastomeric" refers to materials exhibiting elastic properties, which include any material that upon application of a force to its relaxed, initial length can stretch or elongate to an elongated length more than <NUM>% greater than its initial length and will substantially recover back to about its initial length upon release of the applied force.

As used herein, the term "joined" encompasses configurations whereby an element is directly secured to another element by affixing the element directly to the other element, and configurations whereby an element is indirectly secured to another element by affixing the element to intermediate member(s) which in turn are affixed to the other element.

"Longitudinal" means a direction running substantially perpendicular from a waist edge to a longitudinally opposing waist edge of an absorbent article when the article is in a flat out, uncontracted state, or from a waist edge to the bottom of the crotch, i.e. the fold line, in a bi-folded article. Directions within <NUM> degrees of the longitudinal direction are considered to be "longitudinal. " "Lateral" refers to a direction running from a longitudinally extending side edge to a laterally opposing longitudinally extending side edge of an article and generally at a right angle to the longitudinal direction. Directions within <NUM> degrees of the lateral direction are considered to be "lateral.

The term "nonwoven" refers herein to a material made from continuous (long) filaments (fibers) and/or discontinuous (short) filaments (fibers) by processes such as spunbonding, meltblowing, carding, and the like. Nonwovens do not have a woven or knitted filament pattern.

The term "machine direction" (MD) is used herein to refer to the direction of material flow through a process. In addition, relative placement and movement of material can be described as flowing in the machine direction through a process from upstream in the process to downstream in the process.

The term "cross direction" (CD) is used herein to refer to a direction that is generally perpendicular to the machine direction.

The disposable absorbent articles, particularly incontinence pads or pants, of the present disclosure can provide flexibility to allow for an improved and comfortable fit which is less susceptible to bunching during use. In particular, it is envisioned that the articles of the present disclosure exhibit heightened structural resiliency from the proposed configuration and orientation of the layers contained therein while also allowing for conformance of the article.

<FIG> shows an absorbent article <NUM> according to the present disclosure. The absorbent article <NUM> comprises a longitudinal centerline L and a transverse centerline T. The longitudinal centerline L generally extends parallel to the longest dimension of the absorbent article <NUM>. The transverse centerline T extends generally perpendicular to the longitudinal centerline L and lies in the same plane as the absorbent article <NUM> in a flattened state on a flat surface. The transverse centerline T generally bisects the length of the absorbent article <NUM> where the length is parallel to the longitudinal centerline L, and the longitudinal centerline L generally bisects the width of the absorbent article <NUM> where the width is parallel to the transverse centerline T. Additionally, as shown, the MD direction (machine direction) may be generally parallel to the longitudinal centerline L of the absorbent article <NUM>, and the CD direction (cross-machine direction) may be generally parallel to the transverse centerline T.

The absorbent article <NUM> further comprises a chassis <NUM> which comprises a topsheet <NUM>, a backsheet <NUM>, and an absorbent system <NUM> comprising at least one absorbent core sandwiched between the topsheet <NUM> and the backsheet <NUM>. As shown, the topsheet <NUM> forms a portion of a wearer-facing surface <NUM> (the surface of the absorbent article which is disposed most proximal to the wearer during use). And, the backsheet <NUM> forms a portion of a garment-facing surface <NUM> (the surface of the absorbent article which is most proximal to the garment of the wearer during use).

The absorbent system <NUM> may comprise a secondary topsheet <NUM> and at least one absorbent layer <NUM>. As shown, the secondary topsheet <NUM> can be disposed between the topsheet <NUM> and the absorbent layer <NUM>. Additionally, at least one layer of the absorbent system <NUM> may extend longitudinally to a first end <NUM> and/or a second end <NUM> of the absorbent article <NUM>. As shown, the secondary topsheet <NUM> can extend to the first end <NUM> or the second end <NUM>. Or, the secondary topsheet <NUM> and/or additional layers of the absorbent system may extend the full length of the absorbent article <NUM> (first end <NUM> to the second end <NUM> along the longitudinal centerline L).

Additionally, the absorbent article <NUM> further comprises a first side edge <NUM> and a second side edge <NUM>. Each of the first side edge <NUM> and the second side edge <NUM> extend generally parallel to the longitudinal centerline L. It is worth noting however that the first and second side edges are not required to be straight lines. Instead, the first and the second side edges can be curvilinear or any other suitable shape.

A first end edge <NUM> joins the first side edge <NUM> and the second side edge <NUM> in the first end <NUM>. A second end edge <NUM> joins the first side edge <NUM> and the second side edge <NUM> in the second end <NUM>. Cumulatively, the first side edge <NUM>, the second side edge <NUM>, the first end edge <NUM> and the second end edge <NUM> form an outer periphery of the absorbent article <NUM>.

Referring now to <FIG> and <FIG>, the outer periphery of the absorbent article <NUM> generally comprises crimp seals <NUM> and <NUM> which join the topsheet <NUM> and the backsheet <NUM>. The crimp seals <NUM> and <NUM> correspond to the first side edge <NUM> and the second side edge <NUM>. Crimp sealing of the topsheet and backsheet is known in the art. As shown, none of the layers of the absorbent system <NUM> may be disposed within the crimp seals <NUM> and <NUM>. Some suitable examples of crimp sealing are further described in <CIT> and <CIT>. Crimp sealing typically involves the application of heat and pressure to bond materials together. For example, in the case of the crimp seals <NUM> and <NUM>, the topsheet and the backsheet may be bonded together via crimp sealing.

Referring now to <FIG>, the outer periphery of the absorbent article <NUM> also comprises a first end seal <NUM> which corresponds to the first end edge <NUM>. Additionally, the absorbent article <NUM> comprises a second end seal which corresponds to the second end edge <NUM>. In contrast to the crimp seals <NUM> and <NUM>, the first edge seal <NUM> may comprise the secondary topsheet <NUM> in addition to the topsheet <NUM> and the backsheet <NUM>. Similarly, in conjunction with the first edge seal <NUM> or independently thereof, the second edge seal may comprise the secondary topsheet <NUM> along with the topsheet <NUM> and the backsheet <NUM>. It is worth noting that the absorbent layer <NUM> in conjunction with or independent of the secondary topsheet <NUM> may be disposed in at least one of the first or second edge seal.

In general, since the layers of the absorbent system <NUM> are absorbent, manufacturers are hesitant for these materials to be disposed in any crimp / edge seals of the article. Because the layers are absorbent, these layer typically are more efficient at moving liquid insults away from the topsheet toward the absorbent layer <NUM>. Additionally, these layers can sometimes be engineered to spread a liquid insult longitudinally and transversely along the pad so that the more of the absorbent layer <NUM> is effectively utilized. This spreading of liquid insult could occur even in a crimp / edge seal if not carefully designed. Unfortunately, this spreading of the liquid insult could lead to fluid leakage from the article.

However, the inventors have found that when the absorbent article is changed at regular intervals, in accordance with usage instructions, one or more of the layers of the absorbent system <NUM> can be included in the first edge seal and/or second edge seal, while minimizing the risk of fluid leakage from this inclusion. In order to minimize the risk of leakage, one or more of the layers of the absorbent system <NUM> may be phobically treated adjacent the crimp / edge seals. Treatments for the hydrophobic treatment of nonwoven webs are known.

Additionally, absorbent materials typically comprise materials which do not respond positively to crimp sealing. Namely, crimp sealing of absorbent materials typically does not provide sufficient bond strength to maintain product integrity through use. So, where the first edge seal <NUM> and/or the second edge seal comprise the secondary topsheet <NUM> and/or the absorbent layer <NUM>, additional provisions may need to be implemented to ensure that sufficient bond strength is achieved. The inventors have found that a combination of adhesive and crimp sealing can provide sufficient bond strength to the absorbent article.

Referring now to <FIG>, the absorbent article <NUM> may further comprise a visual signal <NUM> that comprises one or more elements. For example, as shown, the visual signal <NUM> may comprise hearts, moons, stars, clouds, rainbows, flowers, the like or combinations thereof. Any suitable design can be utilized. The visual signal <NUM> is visible from the wearer-facing surface <NUM> such that a user can see the visual signal during application of the absorbent article. The visual signal <NUM> has a visual signal length <NUM> which can be determined in accordance with the article length and length of visual signal method as disclosed herein. Similarly, the absorbent article <NUM> can have a length <NUM> which can be determined in accordance with the article length and length of visual signal method as disclosed herein.

The visual signal <NUM> can be provided on a layer of the absorbent system <NUM>, on the underside of the topsheet, and/or a portion of the backsheet. For example, the visual signal <NUM> may be printed on the secondary topsheet <NUM> or may be printed on the absorbent layer <NUM>. However, the visual signal <NUM>, as mentioned previously, should be visible from the wearer-facing surface <NUM>. As such, the layers which comprise the visual signal should be carefully selected to ensure that the printing is visible by the user from the wearer-facing surface <NUM>. Still, the visual signal may be printed on multiple layers of the absorbent system <NUM>. As an example, a portion of the visual signal may be printed on the secondary topsheet <NUM> and another portion of the visual signal may be printed on the absorbent layer <NUM>. If the portion of the visual signal on the absorbent layer <NUM>, is disposed outboard of the bounds of the secondary topsheet <NUM>, then that portion of the visual signal may be visible from the wearer-facing surface <NUM>.

As noted previously, the visual signal can provide the user with reassurance that the absorbent article has sufficient capacity to absorb and retain fluid insults. This is particularly relevant where the overall absorbent product is thin, e.g. less than about <NUM> thick. Because at least one layer of the absorbent system <NUM> extends to the first end <NUM> and/or the second end <NUM>, the visual signal length <NUM> can extend along a larger percentage of the absorbent article length <NUM>. The visual signal length <NUM> is discussed in additional detail hereafter.

In general, thicker pads are perceived by users as having sufficient capacity to absorb liquid insults. Thinner pads, e.g. less than about <NUM> thick, typically have to employ other mechanisms to convince users that the thinner pad has sufficient absorbent capacity. This is typically done via the provision of a visual signal. The inventors have found that the provision of a visual signal can provide the user with confidence that the absorbent article will absorb liquid insults without leaking. For example, the inventors have found that visual signal patterns which resemble walls or boundaries near the extremes of the absorbent article can provide reassurance to the user. In one particular example, arcuate designs near the ends or sides of the absorbent article can be effective at communicating boundaries which can communicate the notion of containment of the liquid insult, e.g. keeping the liquid insult away from the edges of the absorbent article. The provision of this type of visual signal can provide the user with confidence that the fluid will not go beyond the edges of the absorbent system. The inventors have also found that visual signals which are more extensive (cover a higher percentage length of the length of the article) can be more effective at communicating the assurance to the user of the sufficient absorbent capacity of the absorbent article. These longer visual signals can include ovals, arcuate shapes, etc. and may comprise a deep color to help communicate to the user the sufficient absorbent capacity of the absorbent system of the absorbent article. The relationship between visual signal length and caliper is discussed in additional detail hereafter.

It is worth noting that - not according to the claimed invention - visual signals which extend the full length of the pad may be utilized. In such constructions, the layer upon which the visual signal is printed may be printed by a material supplier or by the absorbent article manufacturer. The material supplier or absorbent article manufacturer may print the material of the absorbent system with a visual signal. The absorbent article manufacturer can then cut the printed material to length during processing. However, in order for the visual signal to achieve the resemblance of a boundary, registration of the visual signal may be required. Registration could minimize the likelihood that a portion of the visual signal, e.g. a boundary, is cut off during the manufacturing process.

Referring now to <FIG>, an absorbent article <NUM> may comprise the chassis <NUM> as described herein and may further comprise a pair of non-elasticized barrier cuffs <NUM> and <NUM>. "Nonelasticated" as used herein means the absence of elastic elements beyond the natural elasticity inherently found in the material itself. Thus, the barrier cuffs do not include any rubber thread,.

The first and second barrier cuffs <NUM>, <NUM> are provided at least in a central portion of the absorbent article <NUM>, however, it will be appreciated that the first and second barrier cuffs may extend longitudinally from the first end edge <NUM> to the second end edge <NUM> of the absorbent article. The first and second cuffs <NUM>, <NUM> may be attached directly to the wearer-facing surface <NUM> of the absorbent article, for example, the topsheet <NUM>, or they may be attached at any other point on the absorbent article, for example, to the backsheet <NUM>. The first and second barrier cuffs extend towards the longitudinal centerline of the absorbent article.

Post manufacture, the first and second barrier cuffs typically lie flush with the topsheet, extending upwards only upon disturbance to the pad, for example, by folding for packing or during use by a consumer. The barrier cuffs serve to provide some extra protection to the absorbent article, particularly upon initial insult of the article with, for example, a sudden gush of urine. In such circumstances, it may take some time for the exudates to penetrate the absorbent article and reach the absorbent core. The first and second cuffs help limit sideways leakage from the top surface of the absorbent article.

The first and second cuffs have a proximal end <NUM> and <NUM> attached between the longitudinal centerline and a longitudinal edge of the chassis. Preferably, the proximal end of the respective barrier cuffs is coterminous with the side crimp edge seals <NUM> and <NUM> of the chassis, however, it will be appreciated that the proximal end of the barrier cuffs may also be located inboard of the longitudinal edge of the chassis. A distal end <NUM> of each of the first and second barrier cuffs extends towards the longitudinal centerline of the absorbent article. For the avoidance of doubt, at least in a central section of the absorbent article, the distal end of each of the first and second cuffs is not attached to the topsheet or chassis. Thus, the distal end of the first and second cuffs in at least the central section of the chassis is free to lift up from topsheet, thus impeding lateral flow of exudates from the surface of the absorbent article.

Preferably, the width of the first and second barrier cuffs, i.e., that distance measured between the proximal end and the distal end in a direction substantially orthogonal to the longitudinal centerline is at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>. Without being bound by theory, it is thought that the cuffs need a minimum width to be able to separate from the topsheet and to "stand-up" relative to the topsheet. Where the width of the cuffs varies along the length of the respective cuffs, the width is measured at the lateral center point of the absorbent article. This typically coincides with the minimum width of cuff in the central section of the absorbent article.

Preferably, the distal end of one or both of the first and second barrier cuffs extends over a portion of the absorbent core. Without being bound by theory, it is thought that the differential thickness and stiffness in the core area relative to the chassis increases the ease with which the cuffs may separate from the topsheet and "stand-up" relative to the topsheet. Thus, preferably, the first and second barrier cuffs extend over the absorbent core by at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>. Furthermore, to ensure that a sufficient surface area of the topsheet above the core is exposed to the user's body, the first and second barrier cuffs may extend over a total of between <NUM>% and <NUM>% of the width of the core Wc, as measured at the widest part of the core. At least <NUM>% of the core should remain exposed to enable exudates to be absorbed.

Preferably, the extent to which the first and second barrier cuffs extend over the absorbent core does not exceed <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>% or <NUM>% of the overall width Waa of the absorbent article, as measured at its widest point. For example, for a pad having a maximum width of <NUM>, each cuff would be between <NUM> and <NUM> wide as measured along the widest point WAA of the absorbent article. There is a balance between providing cuffs that are wide enough to hold a sufficient amount of liquid, without being so wide that they become too heavy to lift off the topsheet and/or so wide that they cover the core making it harder for liquids to be absorbed.

The first and second barrier cuffs may be formed of one or more layers of material. Providing more than one layer effectively increases the overall stiffness and strength of the cuff, thus enabling it to more easily separate from the topsheet and therefore stand-up relative to the topsheet, thus providing better protection while in use. The multiple layers also provide better protection against liquid passing through the cuffs and more strength when fluids enter under the cuff.

Where the first and/or second cuffs include multiple layers, the cuffs may be formed of multiple strips of material attached together, either at the attachment strip, or at a distal end. Alternatively, the cuffs may comprise one or more folds formed of a single piece of material to form cuffs with multiple layers. Where the cuff is folded, one, all or select layers of the folded cuff may be attached directly to the chassis. Where the first and second cuffs comprise a single piece of material folded at a distal end of the cuff to form a dual layer cuff, where only one end of the material is attached to the chassis and where the other end of the material is attached to the cuff itself. Where two layers of material make up the cuff and are folded back on one another, then a portion of the combined material is folded back at the distal end.

Providing a fold in the material biases the cuff to more naturally separate itself from the topsheet during use. Without being bound by theory, it is thought that the fold introduces some natural resilient tension into the cuff, such that the cuff has a natural tendency to return to an unfolded state, which causes the cuffs to "stand-up" relative to the topsheet.

Using multiple layers increases the collective stiffness of the cuff relative to using a single layer of material with a higher basis weight. Thus, it is possible to use thinner material, for example, the topsheet material, and to achieve the benefits of a stiffer material that results in separation of the cuffs from the topsheet and enables the cuffs to stand up relative to the topsheet.

The cuffs may be formed of the same material as the topsheet. Using the same material as the topsheet reduces manufacturing costs, for example by enabling bulk order of material and by reducing complexity at the manufacturing line by reducing the number of unwinds (and corresponding space) needed for introducing extra materials. Where the cuffs are formed of the same material as the topsheet, they may be treated to make them phobic.

The first and second cuffs may be made from hydrophilic or hydrophic materials, topsheet or backsheet, Spunbond meltblown spunbond (SMS) or other nonwovens with melt blown layers. The cuffs may also be made of synthetic or natural fibers such as polyethylene, polypropylene, polyester materials, polyamides (e.g., nylon), cotton, silk or pulp which has been spunbonded, carded, melt blown, or a combination of similar known methods. The first and second cuffs may be made from the same material as one of the topsheet or the backsheet, thus reducing raw material costs. Preferably, the cuffs are formed of SMS. Additional disclosure regarding the non-elasticized cuffs is provided in <CIT>, entitled "Absorbent Articles.

In contrast, additional absorbent articles are contemplated which utilize elasticized barrier cuffs. Unlike the non-elasticized cuffs described heretofore, the elasticized cuffs comprise elastic members which can contract and expand. Otherwise the elasticized barrier cuffs may be configured similarly to the non-elasticized barrier cuffs exception the provision of elastic members attached to the cuff material. Additional disclosure regarding absorbent articles with elasticized barrier cuffs can be found in <CIT>.

Additionally, arrays of products are contemplated which include absorbent articles comprising non-elasticized barrier cuffs and elasticized barrier cuffs. For example, absorbent articles can be sized depending upon expected loading. Some users may require an absorbent article with a small amount of absorbency (light absorbency), some may require an intermediate amount of absorbency (medium absorbency), and some may require a high amount of absorbency (high absorbency). It is worth noting that in general, the distinction between light and medium absorbency is via length of the absorbent article. Light absorbency absorbent articles are generally less than <NUM> in length while medium absorbency articles are generally greater than <NUM> in length. High absorbency articles generally are in a different product form than their light and medium counterparts. For example, light and medium absorbency articles are generally in pad form while high absorbency articles are typically in pant form.

The difference between light, medium, and high absorbency articles may be highlighted in packaging via a plurality of droplet icons. As an example, a light absorbent article will have <NUM> droplets highlighted, while a medium absorbency article will have more than two droplets highlighted, e.g. <NUM> or <NUM>, while a high absorbency article will have <NUM> or more droplets highlighted. It is worth noting that droplet icons are not required for this indication, droplet icons are merely an example of an indicator which can be used.

There are several ways to accommodate this variation in needs. One way may be that manufacturer's increase the length of the pads for the various sizes. For example, a user requiring light absorbency may utilize an article having a first length while users requiring medium absorbency may utilize an article having a second length. The second length may be greater than the first length. Another way, to accommodate the variation may be to increase the basis weight of the absorbent layer. For example, an absorbent article for light absorbency may have a first basis weight while another absorbent article for medium absorbency has a second basis weight. The second basis weight may be greater than the first basis weight. Still another way to accommodate the variation in absorbency needs is to provide the user with a combination of the foregoing. For example, variations in article length and absorbent layer basis weights may be provided in an array.

Referring back to <FIG>, arrays of absorbent articles in accordance with the present disclosure, may comprise a plurality of absorbent articles that can accommodate the variation in needs discussed previously. A first plurality of absorbent articles can accommodate light absorbency needs. The first plurality of absorbent articles can have a visual signal length <NUM> determined in accordance with the visual signal length method of between about <NUM> to about <NUM>, more preferably from about <NUM> to about <NUM>, or most preferably from about <NUM> to about <NUM>, specifically including all values within these ranges and any ranges created thereby. The first plurality of absorbent articles can have an overall article length <NUM> of between <NUM> to about <NUM>, more preferably from about <NUM> to about <NUM>, or most preferably from about <NUM> to about <NUM>, specifically reciting all values within these ranges and any ranges created thereby.

A second plurality of absorbent articles can accommodate medium absorbency needs. The second plurality of absorbent articles can have visual signal length <NUM> as determined in accordance with the visual signal length method of between about <NUM> to about <NUM>, more preferably from about <NUM> to about <NUM>, or most preferably from about <NUM> to about <NUM>, specifically reciting all values within these ranges and any ranges created thereby. The second plurality of absorbent articles can have an overall article length <NUM> of between <NUM> to about <NUM>, more preferably from about <NUM> to about <NUM>, or most preferably from about <NUM> to about <NUM>, specifically reciting all values within these ranges and any ranges created thereby.

It should be understood there may be additional pluralities of absorbent articles which can accommodate light absorbency needs. Similarly, there may be additional pluralities of absorbent articles which can accommodate medium absorbency needs. Each of these additional pluralities of articles may have articles lengths as described herein.

The first plurality of absorbent articles and any other plurality of articles which are meant to accommodate light absorbency needs, can comprise the non-elasticized cuffs as disclosed herein. Additionally, or independently thereof, these absorbent articles may comprise a visual signal length <NUM> which is at least about <NUM> percent of the absorbent article length <NUM>, more preferably at least about <NUM> percent, or most preferably about <NUM> percent, specifically reciting all values within these ranges and any ranges created thereby.

Where a number of absorbent article sizes are offered with regard to light absorbency, the visual signal length <NUM> can be at least about <NUM> percent of the absorbent article length <NUM> where the absorbent article length is between about <NUM> and about <NUM>. Where the absorbent article length <NUM> is between about <NUM> to about <NUM>, the visual signal length <NUM> can be at least about <NUM> percent of the absorbent article length <NUM>. Where the absorbent article length <NUM> is between about <NUM> to about <NUM>, the visual signal length <NUM> can be at least about <NUM> percent of the absorbent article length <NUM>. For these articles the visual signal length can be between about <NUM> to about <NUM> or more preferably from about <NUM> to about <NUM>, specifically reciting all values within these ranges and any ranges created thereby.

The second plurality of absorbent articles and any other articles which are meant to accommodate medium absorbency needs, can comprise non-elasticized cuffs. Or, because of the increased capacity of the medium absorbency articles, these absorbent articles may comprise elasticized cuffs. Additionally, or independently thereof, these absorbent articles may comprise a visual signal length <NUM> which is at least about <NUM> percent of the absorbent article length <NUM>, more preferably about <NUM> percent, most preferably at least about <NUM> percent, specifically reciting all values within these ranges and any ranges created thereby.

Where a number of absorbent article sizes are offered with regard to the medium absorbency, the visual signal length <NUM> can be at least about <NUM> percent of the absorbent article length <NUM> where the absorbent article length is between about <NUM> to about <NUM>. Where the absorbent article length <NUM> is between about <NUM> to about <NUM>, the visual signal length <NUM> can be at least about <NUM> percent of the absorbent article length <NUM>. Where the absorbent article length <NUM> is between about <NUM> to about <NUM>, the visual signal length <NUM> can be at least about <NUM> percent of the absorbent article length <NUM>.

Some exemplary article and visual signal lengths are provided below in Table <NUM> with regard to light absorbency articles.

It is worth noting that the difference between the article length (mm) and the visual signal length (mm) can be indicative of the relative distance of the visual signal from an end edge of the absorbent article. For example, for Light <NUM>, the difference between the absorbent article length and the visual signal length is <NUM>. So, the visual signal may be positioned about <NUM> from each end edge of the absorbent article. Of course, the visual signal may be positioned asymmetrically regarding the transverse axis. In such cases, the visual signal may be within about <NUM> of one end of the absorbent article while being within <NUM> of the other end of the absorbent article.

Some exemplary article and visual signal lengths are provided below in Table <NUM> with regard to medium absorbency articles. Additionally, for these articles, theoretical stack up calipers are provided. Theoretical stack up calipers are simply the cumulative calipers based upon target thickness of the components of the absorbent article.

Data regarding visual signals of conventional absorbent articles is provided below in Table <NUM>.

As previously mentioned, thinner articles tend to require more convincing - so to speak - regarding consumer reassurance. Where the absorbent articles have a caliper of less than about <NUM>, the visual signal and the caliper can be related by a performance factor. The performance factor is the difference between the article length and visual signal length (mm) divided by the measured caliper (mm). For the sake of clarity, the difference is divided by the caliper.

As mentioned previously and not according to the claimed invention, utilization of preprinted materials can offer a visual signal which is the full length of the absorbent article. With this in mind, the performance factor (PF) for the absorbent article of the present disclosure can be greater than or equal to <NUM> and less than or equal to <NUM>. The performance factor can be between about <NUM> to about <NUM>, from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>, specifically reciting all values within these ranges and any ranges created thereby.

Referring back now to <FIG>, as mentioned previously, absorbent articles of the present disclosure comprise the chassis <NUM> which comprises the topsheet <NUM>, the backsheet <NUM>, and the absorbent system <NUM> comprising at least one absorbent core sandwiched between the topsheet <NUM> and the backsheet <NUM>. A discussion of each of these items is provided hereafter.

Arrays of products may comprise a plurality of first packages and a plurality of second packages. The plurality of first packages may comprise first absorbent articles, and the plurality of second packages may comprise second absorbent articles. Each of the first absorbent articles are indicated for lower absorbency than each of the second absorbent articles. For example, the plurality of first packages may have <NUM> droplets indicated while the plurality of second packages may have <NUM> droplets highlighted. Further with this example, the first absorbent articles may comprise light absorbency articles, and the second absorbent articles may comprise medium absorbency articles.

The topsheet <NUM> of the chassis <NUM> forms a portion of the wearer-facing surface <NUM>. The topsheet <NUM> may be joined to the absorbent system <NUM> and to the backsheet <NUM> by attachment methods (not shown) such as those well known in the art. Suitable attachment methods are described with respect to joining the backsheet <NUM> to the absorbent system <NUM>. The topsheet <NUM> and the backsheet <NUM> may be joined directly to each other in the incontinence pad periphery and may be indirectly joined together by directly joining them to the absorbent system <NUM>. This indirect or direct joining may be accomplished by attachment methods which are well known in the art.

The absorbent article may comprise any known or otherwise effective topsheet, such as one which is compliant, soft feeling, and non-irritating to the wearer's skin. Suitable topsheet materials include a liquid pervious material that is oriented towards and contacts the body of the wearer permitting bodily discharges to rapidly penetrate through it without allowing fluid to flow back through the topsheet to the skin of the wearer. The topsheet, while being capable of allowing rapid transfer of fluid through it, also provides for the transfer or migration of the lotion composition onto an external or internal portion of a wearer's skin. A suitable topsheet can be made of various materials such as woven and nonwoven materials; apertured film materials including apertured formed thermoplastic films, apertured plastic films, and fiber-entangled apertured films; hydroformed thermoplastic films; porous foams; reticulated foams; reticulated thermoplastic films; thermoplastic scrims; or combinations thereof. Some suitable examples of films that can be utilized as topsheets are described in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>.

Nonlimiting examples of woven and nonwoven materials suitable for use as the topsheet include fibrous materials made from natural fibers, modified natural fibers, synthetic fibers, or combinations thereof. Some suitable examples are described in <CIT>, <CIT>; <CIT>; <CIT>; <CIT>; <CIT>;<CIT>; and<CIT>.

In some forms, the topsheet may comprise tufts as described in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>. The primary topsheet may have a pattern of discrete hair-like fibrils as described in <CIT> or <CIT>. Additional examples of suitable topsheet includes those described in <CIT>; <CIT>; <CIT> and in <CIT>.

Another suitable topsheet or a topsheet combined with a secondary topsheet may be formed from a three-dimensional substrate as detailed in a <CIT>.

The topsheet may have one or more layers, as described in <CIT>; <CIT>; <CIT>. The topsheet may be apertured as disclosed in <CIT>.

The backsheet <NUM> of the chassis <NUM> may form a portion of the garment-facing surface <NUM> of the absorbent article <NUM>. The backsheet <NUM> may be joined to the absorbent system <NUM> by attachment methods (not shown) such as those well known in the art. For example, the backsheet <NUM> may be secured to the absorbent system <NUM> by a uniform continuous layer of adhesive, a patterned layer of adhesive, or an array of separate lines, spirals, or spots of adhesive. Alternatively, the attachment methods may comprise using heat bonds, pressure bonds, ultrasonic bonds, dynamic mechanical bonds, or any other suitable attachment methods or combinations of these attachment methods as are known in the art. Forms of the present disclosure are also contemplated wherein the absorbent system <NUM> is not joined to the backsheet <NUM>, the topsheet <NUM>, or both.

The backsheet <NUM> may be impervious, or substantially impervious, to liquids (e.g., urine) and may be manufactured from a thin plastic film, although other flexible liquid impervious materials may also be used. As used herein, the term "flexible" refers to materials which are compliant and will readily conform to the general shape and contours of the human body. The backsheet <NUM> may prevent, or at least inhibit, the exudates absorbed and contained in the absorbent system <NUM> from wetting articles of clothing which contact the absorbent article <NUM> such as undergarments. However, in some instances, the backsheet <NUM> may permit vapors to escape from the absorbent system <NUM> (i.e., is breathable) while in other instances the backsheet <NUM> may not permit vapors to escape (i.e., non-breathable). Thus, the backsheet <NUM> may comprise a polymeric film such as thermoplastic films of polyethylene or polypropylene. A suitable material for the backsheet <NUM> is a thermoplastic film having a thickness of from about <NUM> (<NUM> mil) to about <NUM> (<NUM> mils), for example. Any suitable backsheet known in the art may be utilized with the present invention.

Some suitable examples of backsheets are described in <CIT>; <CIT>; and <CIT>. Suitable single layer breathable backsheets for use herein include those described for example in <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>; <CIT> and <CIT>; <CIT> and <CIT>.

The backsheet may have two layers: a first layer comprising a gas permeable aperture formed film layer and a second layer comprising a breathable microporous film layer as described in <CIT>. Suitable dual or multi-layer breathable backsheets for use herein include those exemplified in <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, and <CIT>.

As mentioned previously, the absorbent system <NUM> may comprise a plurality of functional layers, e.g. a secondary topsheet and a storage layer. The secondary topsheet <NUM> may be separate and apart from the absorbent system. Additionally, the secondary topsheet may be disposed beneath the topsheet <NUM> and on a body-facing surface of the absorbent system <NUM>. The secondary topsheet <NUM> can server a multitude of functions. First, the secondary topsheet <NUM> can quickly drain the topsheet from any liquid insults that may be imparted to the topsheet. Second, the secondary topsheet <NUM> can distribute liquid insults so that the storage layer is utilized more effectively. Namely, the liquid insult may be distributed to a larger area than the expected liquid insult region of the absorbent article.

To accommodate the above functionality, the secondary topsheet may comprise a nonwoven material which comprises a variety of fiber types. For example, the secondary topsheet may comprise absorbing fibers, resilient fibers and stiffening fibers. The absorbing fibers may comprise cellulose or viscose, as an example. The resilient fibers and stiffening fibers may be synthetic. The resilient fibers can help the secondary topsheet retain it void volume by resisting collapsing forces. The stiffening fibers may be bicomponent fibers which can be fused to one another to create a matrix of fiber interconnections. These fiber interconnections can provide the secondary topsheet with stiffening properties.

The secondary topsheet may have a basis weight from about <NUM> gsm to about <NUM> gsm, from about <NUM> gsm to about <NUM> gsm, or from about <NUM> gsm to about <NUM> gsm, specifically including all values within these ranges and any ranges created thereby.

Some exemplary secondary topsheets are described in <CIT>; <CIT>; <CIT>; and <CIT>.

Referring now to <FIG> and <FIG>, the absorbent system <NUM> either in conjunction with or independently thereof, may comprise a first absorbent core <NUM> and/or a second absorbent core <NUM>. While the first absorbent core <NUM> and the second absorbent core <NUM> are shown as rectangular with rounded ends, any suitable shape may be utilized. Some examples include offset hourglass (one end is wider than an opposite end and a narrowed mid-section between the ends), bicycle seat shape (one end and central portion are narrower than second end), etc. Side edges <NUM> and <NUM> may follow the general contour of the first absorbent core <NUM> and/or the second absorbent core <NUM>. So where, the first absorbent core <NUM> and/or the second absorbent core <NUM> are an hourglass shape, the side edges <NUM>, <NUM> may be arranged in an hourglass shape as well. However, the side edges <NUM> and <NUM> may be generally straight or slightly curved such that they do not follow the contour of the first absorbent core <NUM> and/or the second absorbent core <NUM>. Additional details are discussed hereafter. The absorbent article <NUM> may be symmetric about the longitudinal centerline L or asymmetric about the longitudinal centerline L. Similarly, the absorbent article <NUM> may be symmetric about the transverse centerline T or asymmetric about the transverse centerline T.

As shown, the first absorbent core <NUM> may be positioned in absorbent article more proximal to a wearer-facing surface than the second absorbent core <NUM>. However, forms are contemplated where the second absorbent core <NUM> is positioned in the absorbent article more proximal to a wearer-facing surface than the first absorbent core <NUM>.

The first absorbent core <NUM> may comprise side edges <NUM> and <NUM> and a pair of end edges <NUM> and <NUM> which join the side edges <NUM> and <NUM> adjacent the first end <NUM> and adjacent the second end <NUM> of absorbent article <NUM>, respectively. Similarly, the second absorbent core <NUM> may comprise side edges <NUM> and <NUM> and a pair of end edges <NUM> and <NUM> which join the side edges <NUM> and <NUM> adj acent the first end <NUM> and the second end <NUM> of the absorbent article <NUM>, respectively. As shown, the first absorbent core <NUM> has a first width <NUM> and the second absorbent core <NUM> comprises a second width <NUM>. As shown, the first width <NUM> may be greater than the second width <NUM>.

The first absorbent core <NUM> can have a width <NUM> ranging from about <NUM> to about <NUM>. The second absorbent core <NUM> can have a width <NUM> which ranges from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, specifically reciting all values within these ranges and any ranges created thereby.

Additionally, as shown the end edges <NUM> and <NUM> of the first absorbent core <NUM> may be substantially flat. End edges <NUM> and <NUM> of the second absorbent core <NUM> may be similarly configured. Moreover, as shown, end edge <NUM> of the first absorbent core <NUM> may be coterminous with end edge <NUM> of the second absorbent core <NUM>. Or, the first absorbent core <NUM> and the second absorbent core <NUM> may be positioned within the absorbent article <NUM> such that the first absorbent core <NUM> is offset from the second absorbent core <NUM>. Such configuration is explained in additional detail hereafter.

Where the first absorbent core <NUM> and the second absorbent core <NUM> are offset from one another, the amount of the second absorbent core <NUM> outboard of the first absorbent core <NUM> can be constant along the length of the first absorbent core <NUM>. In such forms, it is believed that a minimum portion of the second absorbent core <NUM> outboard of the first absorbent core <NUM> is greater than <NUM>. It is believed that this minimum distance can be beneficial in allowing sufficient conformance of the absorbent article. However, forms are contemplated where the portion of the second absorbent core <NUM> outboard of the first absorbent core <NUM> may be variable depending on location. Examples regarding this aspect of the absorbent article of the present disclosure are provided hereafter.

Referring now to <FIG>, <FIG>, and <FIG>, a cross section of an exemplary absorbent system <NUM> taken along a longitudinal centerline is shown. As noted previously, the absorbent system <NUM> may comprise a first absorbent core <NUM> and a second absorbent core <NUM>. As shown, the first absorbent core <NUM> has an upper surface 460A and a lower surface 460B which opposes the upper surface. Similarly, the second absorbent core <NUM> has an upper surface 470A and a lower surface 470B. Additionally, the first absorbent core <NUM> and/or the second absorbent core <NUM> may comprise a laminate structure which includes a plurality of layers. Such forms are discussed in additional detail hereafter.

As shown, the first absorbent core <NUM> may be joined to the second absorbent core <NUM> in an offset manner or configuration along the length of the absorbent system <NUM>. As used herein "offset" or "offset manner" means that the layers of interest are staggered and that their respective end edges are not aligned in a z-direction (i.e., the end edge of one layer or laminate structure is not coterminous with the end edge of an adjacent underlying or overlying layer or laminate structure) when the layers or laminate structures overlay one another. This offset joinder of the first and second absorbent core <NUM> and <NUM> results in an overlapping and joined area of the two layers that forms a central portion 205C of the absorbent system <NUM>. The central portion 205C of the absorbent system <NUM> is consequently bounded on each side by a front end portion 205F and a rear end portion 205R, both of the absorbent system <NUM>. In other words, the front end portion 205F and the rear end 205R portion are respectively disposed at opposing ends of the absorbent system <NUM>. As shown, a distance between the end edge <NUM> and the end edge <NUM> can define a length of the front end portion 205F. Similarly, a distance between the end edge <NUM> and the end edge <NUM> can define a length of the rear end portion 205R. The end edge <NUM> may be the leading edge (more proximal to the first end <NUM> of the pad <NUM>) of the absorbent system <NUM> while the end edge <NUM> may be the trailing edge (more proximal to the second end <NUM> of the pad <NUM>) of the absorbent system <NUM>.

The length of the central portion 205C can vary by size of the absorbent article <NUM>. For example, for those absorbent articles sized for higher BMI wearers, the length of the central portion 205C can be higher than the central portion 205C for absorbent articles sized for wearers having a lower BMI. Additionally, where the absorbent articles are equipped with elasticated barrier leg cuffs, the central portion 205C may extend past the outermost anchor points of the elastomeric members of the barrier leg cuffs. Extension of the central portion 205C past these outermost anchor points can reduce the likelihood of the ends of the absorbent article folding during application of the absorbent article. Folding ends during application of the absorbent article can be problematic as described in <CIT>. In some forms, the central portion 205C may have a length of at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>, specifically including all values within these ranges and any ranges created thereby.

It is worth noting that where the first absorbent core <NUM> and the second absorbent core <NUM> are positioned in an offset manner and are adhesively attached, care should be taken as to how the adhesive is applied. adhesive applied to the lower surface 460B should be strategically positioned to reduce the likelihood of contamination of the equipment. For example, as shown, adhesive applied in the front end portion 205F could contaminate the equipment as the second absorbent core <NUM> does not overly the adhesive in that area. Adhesive is needed in the central portion 205C. Additionally, adhesive should be provided in the rear end portion 205R. In such forms, adhesive would be applied to the carrier web to ensure that the second absorbent core <NUM> releases completely from a cut-and-slip or cut-and-lay operation. Where the second leading edge <NUM> forms the front end portion 205F, adhesive should be applied to the carrier web in the front end portion 205F and the central portion 205C to ensure that the second leading edge <NUM> is released from the cut-and-slip or cut-and-lay operation. Cut-and-slip and cut-and-lay devices are well known in the art.

Referring now to <FIG>, a first absorbent core <NUM> and/or a second absorbent core <NUM> may comprise a plurality of webs and layers themselves. For example, the first absorbent core <NUM> may comprise a first superabsorbent layer <NUM> disposed on a first distribution layer <NUM>, i.e. a first absorbent core laminate <NUM>. And, the second absorbent core <NUM> may comprise a second superabsorbent layer <NUM> disposed on a second distribution layer <NUM>, i.e. a second absorbent core laminate <NUM>. In some forms, the first distribution layer <NUM> is joined to the second distribution layer <NUM> in an offset manner or configuration along the length of the core. This offset joinder of the first and second distribution layers <NUM>, <NUM> results in an overlapping and joined area of the two laminates that forms the central portion 205C of the absorbent system <NUM>. As shown, the front end portion 205F is formed from the end edge <NUM> of the first absorbent core laminate <NUM> and the end edge <NUM> of the second absorbent core laminate <NUM>. The rear end portion 205R of the absorbent system <NUM> is formed by the end edge <NUM> of the second absorbent core laminate <NUM> and the end edge <NUM> of the first absorbent core laminate <NUM>. It is worth noting that configurations are contemplated where the first distribution layer <NUM> is joined to the second super absorbent layer <NUM> rather than the second distribution layer <NUM>. In such forms, the laminates may be joined to one another in an offset manner as well except the first distribution layer <NUM> is joined to the second superabsorbent layer <NUM> instead of the second distribution layer <NUM>. Additionally, configurations are contemplated where at least one of the layers of the absorbent system <NUM> comprises a single layer, e.g. a superabsorbent layer or a distribution layer, while the other comprises a laminate structure as described herein.

As shown, the end edge <NUM> and end edge <NUM> of the first and second absorbent core laminates oppose each other and form the front end portion 205F and the rear end portion 205R of the absorbent system <NUM>, respectively or vice versa. In other forms, the end edge <NUM> and end edge <NUM> of the first and second absorbent core laminates may oppose each other and form a front end portion 205F and a rear end portion 205R of the absorbent system <NUM>, respectively or vice versa. In both instances, the end edge <NUM> and end edge <NUM> may be in the form of a male connection derived from a nested cut of the first and second absorbent cores. Similarly, the end edge <NUM> and end edge <NUM> may be in the form of a female connection derived from a nested cut of the first and second laminates, respectively.

In some forms, the overlapping area or region that forms the central portion 205C of the absorbent system <NUM> has at least one characteristic of a greater capacity, a greater void volume, or a greater thickness than the front end portion 205F and the rear end portion 205F of the absorbent system <NUM>. These forms may be particularly useful for providing for heightened leakage protection in the central portion where female users of such pads would typically contact the pad along with increased flexibility in the front end portion and rear end portion.

The configuration and construction of the absorbent system <NUM> may vary (e.g., the absorbent system <NUM> may have varying caliper zones, a hydrophilic gradient, a superabsorbent gradient, or lower average density and lower average basis weight acquisition zones). Further, the size and absorbent capacity of the absorbent system <NUM> may also be varied to accommodate a variety of wearers. However, the total absorbent capacity of the absorbent system <NUM> should be compatible with the design loading and the intended use of the disposable absorbent article <NUM>.

The absorbent system <NUM> may comprise a plurality of multi-functional layers that are in addition to the first and second absorbent cores. For example, the absorbent system <NUM> may comprise a core wrap (not shown) useful for enveloping the first and second laminates and other optional layers. The core wrap may be formed by two nonwoven materials, substrates, laminates, films, or other materials. In a form, the core wrap may only comprise a single material, substrate, laminate, or other material wrapped at least partially around itself.

The absorbent system <NUM> of the present disclosure may comprise one or more adhesives, for example, to help immobilize the SAP or other absorbent materials within the first and second laminates.

Absorbent cores comprising relatively high amounts of SAP with various core designs are disclosed in <CIT>, <CIT>; <CIT>; <CIT>; and <CIT>. These may be used to configure the superabsorbent layers.

Additions to the core of the present disclosure are envisioned. In particular, potential additions to the current multi-laminate absorbent core are described in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>. These are useful to the extent they do not negate or conflict with the effects of the below described layers of the absorbent core of the present invention.

The first and second absorbent cores layers and/or laminates of the absorbent system <NUM> have been detailed earlier but it is important to note that these layers or laminates may have cross-direction widths that are the same as each other or different. As discussed previously, for example, the first absorbent core layer or laminate may have a lesser cross-direction width than said second absorbent core layer or laminate or a greater cross-direction width than said second absorbent core layer or laminate. In certain instances, the first and second absorbent core layers or laminates can have machine-direction lengths that are the same while in other instances, the first and second absorbent cores have machine-direction lengths that are different. In the latter instance, the first absorbent core layer or laminate may have a lesser machine-direction length than the second absorbent core layer or laminate, or conversely the first absorbent core layer or laminate may have a greater machine-direction length than said second absorbent core layer or laminate.

The first and second absorbent core layers or laminates may further comprise an optional intermediate layer disposed between the respective superabsorbent layer and distribution layer. This optional intermediate layer may comprise materials detailed herein relative to the optional layers for the chassis, in general.

As stated previously, in some forms, the first absorbent core layer or laminate has end edge <NUM> that is complementary in shape to its respective end edge <NUM>. More specifically, the end edge <NUM> of the first absorbent core layer or laminate may conform shape wise to the end edge <NUM> of the same. The same conformance may apply to the second absorbent core layer or laminate. This conformation results from a nested cut of the first absorbent core layer or laminate and the second absorbent core layer or laminate that provides matching or shape fitting ends. Likewise, this feature may also be prevalent in any optional absorbent cores that might be incorporated into the absorbent system. This nesting or nested cut feature of the absorbent cores allow for reduced waste of trim during manufacture. It has also been found that it is possible to configure the first and second absorbent core layers or laminates in a manner that allows for their respective convex edges to oppose one another when the first and second layers are overlapped and joined forming an absorbent system with a central portion 205C comprising an overlapping area.

Referring to <FIG>, as noted previously, the front end portion of the absorbent system 205F can be formed from end edge <NUM> or end edge <NUM> of either the first absorbent core or the second absorbent core. A rear end portion of the absorbent system 205R may similarly be formed from end edge <NUM> or end edge <NUM> of the other of the first absorbent core or the second absorbent core. This configuration yields an absorbent system with matching (i.e., a male connection) ends. In other forms, a front end portion of the absorbent system may be formed from end edge <NUM> or end edge <NUM> of either the first absorbent core or the second absorbent core while the rear end portion of the absorbent system is formed from end edge <NUM> or end edge <NUM> of the other of the first absorbent core or second absorbent core. In such forms, the second end is shaped as a female connection and therefore does not match the front end portion of the same core. In other forms, the front end portion of the absorbent system may be formed from the end edge <NUM> of the first absorbent core or end edge <NUM> of the second absorbent core. A rear end portion of the absorbent system may be similarly formed from the end edge <NUM> of the remaining first absorbent core or the end edge <NUM> of the second absorbent core. This configuration yields an absorbent system with matching (i.e., a female connection) ends. It should be noted, however, that the width of the first and second absorbent cores may be the same or different as mentioned herein. The nested cuts of the end edges of each of the first and second absorbent cores can have shapes selected from the group consisting of arcs, semicircles, semi-ellipses, chevrons, rectangles, sinusoids, jigsaws, and combinations thereof.

In some forms, the first or second absorbent cores may include one or more recessed areas that run along the machine direction or cross direction. These recessed areas may coincide with the discontinuous patterns of one or more of a superabsorbent layer and distribution layer, whether it be of the first absorbent core, second absorbent core, or both. These recessed areas may also merely be formed by embossing of the first or second absorbent cores. These recessed areas may alternatively be formed by slitting, cutting, ring-rolling, or otherwise providing mechanical deformation through the first and/or second absorbent cores. Each manner of recessed area formation mentioned herein is intended to yield a recessed area that is capable of providing a point of preferential bending of the overall article.

Additionally, for those forms where the first absorbent core and/or the second absorbent core do not comprise laminate structures, an airlaid core material can be utilized. Any suitable airlaid core can be utilized. Airlaid core material can be obtained by a manufacturer of such materials or can be made online via equipment known in the art. Where an airlaid core is utilized, the need for separate superabsorbent layers and distribution layers may be reduced. In such forms, the absorbent core web <NUM> (shown in <FIG>) may comprise an airlaid web as described herein. Suitable airlaid absorbent core structures are disclosed in <CIT> and <CIT> and <CIT>.

Referring to <FIG> and <FIG>, the first and second superabsorbent layers <NUM>, <NUM> of the first and second absorbent core laminates <NUM>, <NUM> comprise superabsorbent polymers or absorbent gelling materials (AGM). In some forms, the superabsorbent layer <NUM> and/or <NUM> may comprise the carrier web and composition. In such forms, superabsorbent may be deposited on the carrier web to form the superabsorbent layers. The superabsorbent layers may comprise AGM particles or AGM fibers. In general, such AGM's have been used only for their fluid-absorbing properties. Such materials form hydrogels on contact with liquid (e.g., with urine, blood, and the like). One highly preferred type of hydrogel-forming, absorbent gelling material is based on the hydrolyzed polyacids, especially neutralized polyacrylic acid. Hydrogel-forming polymeric materials of this type are those which, upon contact with fluids (i.e., liquids) such as water or body fluids, imbibe such fluids and thereby form hydrogels. In this manner, fluid discharged into the fluid absorbent structures herein can be acquired and held. These preferred superabsorbent polymers will generally comprise substantially water-insoluble, slightly cross-linked, partially neutralized, hydrogel-forming polymer materials prepared from polymerizable, unsaturated, acid-containing monomers.

The size of the fluid absorbent gelling material particles may vary over a wide range. For reasons of industrial hygiene, average particle sizes smaller than about <NUM> microns are less desirable. Particles having a smallest dimension larger than about <NUM> may also cause a feeling of grittiness in the absorbent article, which is undesirable from a consumer aesthetics standpoint. Furthermore, rate of fluid absorption can be affected by particle size. Larger particles have very much reduced rates of absorption. Fluid absorbent gelling material particles preferably have a particle size of from about <NUM> microns to about <NUM> for substantially all of the particles. "Particle Size" as used herein means the weighted average of the smallest dimension of the individual particles.

In some forms, the absorbent cores or portions thereof of the present disclosure may be substantially free of airfelt and are thus distinct from mixed layers that may include airfelt. As used herein, "substantially free of airfelt" means less than <NUM>%, <NUM>%, <NUM>%, or even <NUM>% of airfelt. In some forms, there may be no measurable airfelt in the superabsorbent layers. In the case of the first superabsorbent layer, it is preferably disposed onto the first distribution layer discontinuously. And as noted previously, the second superabsorbent layer may, in conjunction with the first superabsorbent layer or independently thereof, be disposed on the second distribution layer discontinuously. As used herein "discontinuously" or "in a discontinuous pattern" means that the superabsorbent polymers are applied onto the first distribution layer in a pattern of disconnected shaped areas. These areas of superabsorbent polymers or areas free of superabsorbent polymer may include, but are not limited to linear strips, non-linear strips, circles, rectangles, triangles, waves, mesh, and combinations thereof. The first superabsorbent layer like the second superabsorbent layer may, however, be disposed onto its respective distribution layer in a continuous pattern. As used herein "continuous pattern" or "continuously" means that the material is deposited and or secured to a superabsorbent carrier material and/or the adjacent distribution layer in an uninterrupted manner such that there is rather full coverage of the distribution layer by the superabsorbent polymer.

In some forms, the first and second superabsorbent layers may comprise superabsorbent polymers that are the same. In other embodiments, the first and second superabsorbent layers may comprise superabsorbent polymers that are different from one another. This is may be in addition to the different deposition patterns that are discussed above.

The superabsorbent layers are disposed having a thickness of <NUM>, <NUM>, <NUM>, or <NUM> to <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. The first and second superabsorbent layers may have the same or different cross-direction widths as applied to their respective distribution layers. For instance, the cross-direction widths of the first and second superabsorbent layers may be from <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> to <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. Alternatively, in embodiments where the widths of the first and second superabsorbent layers differ from one another in the cross-direction width, the first superabsorbent layer may have a lesser cross-direction width than the second superabsorbent layer. In particular, the first superabsorbent layer may have a cross-direction width that is less than about <NUM>%, <NUM>%, <NUM>%, <NUM>%, or even <NUM>% of the width of the second superabsorbent layer.

In certain embodiments, the one or both of the first and second superabsorbent layers span greater than greater than about <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or even <NUM>% of the cross-direction width of a superabsorbent carrier layer and/or the respective adjoining first or second distribution layer.

The super absorbent layers may further comprise a nonwoven carrier web. Carrier webs may be webs selected from the group consisting of a fibrous structure, an airlaid web, a wet laid web, a high loft nonwoven, a needle punched web, a hydroentangled web, a fiber tow, a woven web, a knitted web, a flocked web, a spunbond web, a layered spunbond/ melt blown web, a carded fiber web, a coform web of cellulose fiber and melt blown fibers, a coform web of staple fibers and melt blown fibers, and layered webs that are layered combinations thereof.

Carrier webs may comprise materials such as creped cellulose wadding, fluffed cellulose fibers, airfelt, and textile fibers. The materials of the webs may also be fibers such as, for example, synthetic fibers, thermoplastic particulates or fibers, tricomponent fibers, and bicomponent fibers such as, for example, sheath/core fibers having the following polymer combinations: polyethylene/polypropylene, polyethylvinyl acetate/polypropylene, polyethylene/polyester, polypropylene/polyester, copolyester/polyester, and the like. The optional layers may be any combination of the materials listed above and/or a plurality of the materials listed above, alone or in combination. The materials of the webs may be hydrophobic or hydrophilic depending on their placement within the chassis.

The materials of the webs may comprise constituent fibers comprising polymers such as polyethylene, polypropylene, polyester, and blends thereof. The fibers may be spunbound fibers. The fibers may be meltblown fibers. The fibers may comprise cellulose, rayon, cotton, or other natural materials or blends of polymer and natural materials. The fibers may also comprise a superabsorbent material such as polyacrylate or any combination of suitable materials. The fibers may be monocomponent, bicomponent, and/or biconstituent, non-round (e.g., capillary channel fibers), and may have major cross-sectional dimensions (e.g., diameter for round fibers) ranging from <NUM>-<NUM> microns. The constituent fibers of the nonwoven precursor web may also be a mixture of different fiber types, differing in such features as chemistry (e.g. polyethylene and polypropylene), components (mono- and bi-), denier (micro denier and ><NUM> denier), shape (i.e., capillary and round) and the like. The constituent fibers may range from about <NUM> denier to about <NUM> denier.

The webs may include thermoplastic particulates or fibers. The materials, and in particular thermoplastic fibers, may be made from a variety of thermoplastic polymers including polyolefins such as polyethylene (e.g., PULPEX™) and polypropylene, polyesters, copolyesters, and copolymers of any of the foregoing.

Depending upon the desired characteristics, suitable thermoplastic materials include hydrophobic fibers that have been made hydrophilic, such as surfactant-treated or silica-treated thermoplastic fibers derived from, for example, polyolefins such as polyethylene or polypropylene, polyacrylics, polyamides, polystyrenes, and the like. The surface of the hydrophobic thermoplastic fiber may be rendered hydrophilic by treatment with a surfactant, such as a nonionic or anionic surfactant, e.g., by spraying the fiber with a surfactant, by dipping the fiber into a surfactant or by including the surfactant as part of the polymer melt in producing the thermoplastic fiber. Upon melting and resolidification, the surfactant will tend to remain at the surfaces of the thermoplastic fiber. Suitable surfactants include nonionic surfactants such as Brij <NUM> manufactured by ICI Americas, Inc. of Wilmington, Del. , and various surfactants sold under the Pegosperse™ by Glyco Chemical, Inc. of Greenwich, Conn. Besides nonionic surfactants, anionic surfactants may also be used. These surfactants may be applied to the thermoplastic fibers at levels of, for example, from about <NUM> to about <NUM>/cm<NUM> of thermoplastic fiber.

Suitable thermoplastic fibers may be made from a single polymer (monocomponent fibers) or may be made from more than one polymer (e.g., bicomponent fibers). The polymer comprising the sheath often melts at a different, typically lower, temperature than the polymer comprising the core. As a result, these bicomponent fibers provide thermal bonding due to melting of the sheath polymer, while retaining the desirable strength characteristics of the core polymer.

Suitable bicomponent fibers for use in the webs of this disclosure may include sheath/core fibers having the following polymer combinations: polyethylene/polypropylene, polyethylvinyl acetate/polypropylene, polyethylene/polyester, polypropylene/polyester, copolyester/polyester, and the like. Particularly suitable bicomponent thermoplastic fibers for use herein are those having a polypropylene or polyester core, and a lower melting copolyester, polyethylvinyl acetate or polyethylene sheath (e.g., DANAKLON™, CELBOND™, or CHISSO™ bicomponent fibers). These bicomponent fibers may be concentric or eccentric. As used herein, the terms "concentric" and "eccentric" refer to whether the sheath has a thickness that is even, or uneven, through the cross-sectional area of the bicomponent fiber. Eccentric bicomponent fibers may be desirable in providing more compressive strength at lower fiber thicknesses. Suitable bicomponent fibers for use herein may be either uncrimped (i.e., unbent) or crimped (i.e., bent). Bicomponent fibers may be crimped by typical textile means such as, for example, a stuffer box method or the gear crimp method to achieve a predominantly two-dimensional or "flat" crimp.

The length of bicomponent fibers may vary depending upon the particular properties desired for the fibers and the web formation process. Typically, in an airlaid web, these thermoplastic fibers have a length from about <NUM> to about <NUM> long such as, for example, from about <NUM> to about <NUM> long, and from about <NUM> to about <NUM> long. Nonwoven fibers may be between <NUM> long and <NUM> long, such as, for example, <NUM> long, <NUM> long, <NUM> long, <NUM> long, <NUM> long, <NUM> long, <NUM> long, <NUM> long, <NUM> long, <NUM> long, <NUM> long, <NUM> long, or <NUM> long. The properties-of these thermoplastic fibers may also be adjusted by varying the diameter (caliper) of the fibers. The diameter of these thermoplastic fibers is typically defined in terms of either denier (grams per <NUM> meters) or decitex (grams per <NUM>,<NUM> meters). Suitable bicomponent thermoplastic fibers as used in an airlaid making machine may have a decitex in the range from about <NUM> to about <NUM> such as, for example, from about <NUM> to about <NUM>, and from about <NUM> to about <NUM> decitex.

The compressive modulus of these thermoplastic materials, and especially that of the thermoplastic fibers, may also be important. The compressive modulus of thermoplastic fibers is affected not only by their length and diameter, but also by the composition and properties of the polymer or polymers from which they are made, the shape and configuration of the fibers (e.g., concentric or eccentric, crimped or uncrimped), and like factors. Differences in the compressive modulus of these thermoplastic fibers may be used to alter the properties, and especially the density characteristics, of the respective thermally bonded fibrous matrix.

The webs may also include synthetic fibers that typically do not function as binder fibers but alter the mechanical properties of the fibrous webs. Synthetic fibers include cellulose acetate, polyvinyl fluoride, polyvinylidene chloride, acrylics (such as Orlon), polyvinyl acetate, nonsoluble polyvinyl alcohol, polyethylene, polypropylene, polyamides (such as nylon), polyesters, bicomponent fibers, tricomponent fibers, mixtures thereof and the like. These might include, for example, polyester fibers such as polyethylene terephthalate (e.g., DACRON™, and KODEL™), high melting crimped polyester fibers (e.g., KODEL™ <NUM> made by Eastman Chemical Co. ) hydrophilic nylon (HYDROFIL™), and the like. Suitable fibers may also hydrophilized hydrophobic fibers, such as surfactant-treated or silica-treated thermoplastic fibers derived from, for example, polyolefins such as polyethylene or polypropylene, polyacrylics, polyamides, polystyrenes, polyurethanes and the like. In the case of nonbonding thermoplastic fibers, their length may vary depending upon the particular properties desired for these fibers. Typically they have a length from about <NUM> to <NUM>, such as, for example from about <NUM> to about <NUM>. Suitable nonbonding thermoplastic fibers may have a decitex in the range of about <NUM> to about <NUM> decitex, such as, for example, from about <NUM> to about <NUM> decitex.

The first and second distribution layers are useful for wicking bodily fluids away from the skin of a wearer to facilitate comfort of continued wear after a release. In some forms, the support web may comprise the distribution layer. In some forms, the support web may be configured similar to the carrier web described herein. In some forms, the first and second distribution layers of the first and/or second laminates not only face one another but are joined in an offset manner to form part of the core. The distribution layers comprise one or more of cellulose and commuted wood pulp. This may be in the form of airlaid. The airlaid may be chemically or thermally bonded. In particular, the airlaid may be multi bonded airlaid (MBAL). In this instance, the distribution layer may further comprise a fibrous thermoplastic adhesive material at least partially bonding the airlaid to itself and adjacent distribution layers, superabsorbent layers, or other additional (optional) layers. It should be noted that the same materials that are suitable for the optional layers of the chassis are envisioned as suitable for use in the distribution layers. The basis weight for each of the first and second distribution layers range from 80gsm, <NUM> gsm, 100gsm, <NUM> gsm, 120gsm, or <NUM> gsm to <NUM> gsm, <NUM> gsm, <NUM> gsm, <NUM> gsm, <NUM> gsm, <NUM> gsm, or <NUM> gsm. A preferred basis weight is <NUM> gsm for each of the distribution layers of the first and second laminates. Forms are contemplated where the absorbent core web <NUM> (shown in <FIG>) comprises a laminate structure of a superabsorbent layer and a distribution layer.

Linear distances may be measured by any appropriate instrument that is calibrated and capable of a measurement to the nearest <NUM>. Area measurements are made using the projected area of the article, as viewed orthogonally to the plane of the longitudinal and transverse axes, in square millimeters to the nearest <NUM><NUM>.

The overall length of an absorbent article is measured as the distance between the front leading edge and rear leading edge along the longitudinal centerline of the absorbent article. The overall length of the visual signal that is visible on the wearer-facing side of the absorbent article is measured as the distance between the endpoint of the signal closest to the front leading edge of the article and the endpoint of the signal closest to the rear leading edge of the article, along an axis that is parallel to the longitudinal axis of the article. The length of the visual signal is taken as the maximum length that the printed signal covers in the longitudinal direction of the absorbent article, even if this maximum length does not occur directly at the longitudinal centerline. All testing is performed in a room maintained at a temperature of <NUM>° C ± <NUM>° C and a relative humidity of <NUM>% ± <NUM>% and samples are conditioned under the same environmental conditions for at least <NUM> hours prior to testing.

To prepare the test sample, first remove it from any wrapper present and remove the release paper, if necessary, to expose the Panty Fastening Adhesive (PFA) on the garment-facing side of the absorbent article. Apply a light dusting of talc powder to the PFA to mitigate tackiness. Suspend the article vertically by its front leading edge. Attach a <NUM> ± <NUM> weight to the rear leading edge allowing the article to hang freely. After <NUM> seconds, measure the length of the article along the longitudinal centerline using a calibrated steel metal ruler traceable to NIST, or equivalent. Record as Article Length to the nearest <NUM>.

Now mount the article on a flat metal plate that is approximately <NUM> thick with a length and width larger than the article. Using masking tape (about <NUM> wide), secure the article to the center of the metal plate as follows. With the garment-facing side of the article facing the metal plate, attach a strip of tape across the front leading edge of the article in such a way that no portion of the tape overlaps the printed visual signal. In like fashion, the rear leading edge of the article is secured to the metal plate such that the article is extended to the previously measured Article Length. Determine the endpoint of the printed visual signal that is closest to the front leading edge, then draw a straight, fine line at this endpoint that is perpendicular to the longitudinal axis of the article. In like fashion, draw another fine line at the rear leading edge that corresponds to the endpoint of the visual signal. Using a calibrated steel metal ruler traceable to NIST, or equivalent, measure the distance between the visual signal endpoint lines along an axis that is parallel to the longitudinal axis of the article. Record as Visual Signal Length to the nearest <NUM>. The percentage of the Visual Signal Length versus the Article Length is calculated as follows <MAT> and reported as % Visual Signal Length to the nearest <NUM> %.

In like fashion, a total of five replicate test samples are prepared and analyzed. The arithmetic mean is calculated for % Visual Signal Length and reported to the nearest <NUM>%.

The thickness of a test specimen is measured as the distance between a reference platform on which the specimen rests and a pressure foot that exerts a specified amount of pressure onto the specimen over a specified amount of time. All measurements are performed in a laboratory maintained at <NUM> ± <NUM> C° and <NUM>% ± <NUM>% relative humidity and test specimens are conditioned in this environment for at least <NUM> hours prior to testing.

Specimen thickness is measured with a manually-operated micrometer equipped with a pressure foot capable of exerting a steady pressure of <NUM> psi ± <NUM> psi onto the test specimen. The manually-operated micrometer is a dead-weight type instrument with readings accurate to <NUM>. A suitable instrument is Mitutoyo Series <NUM> ID-C Digimatic, available from VWR International, or equivalent. The pressure foot is a flat ground circular movable face with a diameter that is smaller than the test specimen and capable of exerting the required pressure. A suitable pressure foot has a diameter of <NUM>; however, a smaller or larger foot can be used depending on the size of the specimen being measured. The test specimen is supported by a horizontal flat reference platform that is larger than and parallel to the surface of the pressure foot. The system is calibrated and operated per the manufacturer's instructions.

Obtain a test specimen by removing it from an absorbent article, if necessary. When excising the test specimen from an absorbent article, use care to not impart any contamination or distortion to the test specimen layer during the process. The test specimen is obtained from an area free of folds or wrinkles, and it must be larger than the pressure foot.

To measure thickness, first zero the micrometer against the horizontal flat reference platform. Place the test specimen on the platform with the test location centered below the pressure foot. Gently lower the pressure foot with a descent rate of <NUM> ± <NUM> per second until the full pressure is exerted onto the test specimen. Wait <NUM> seconds and then record the thickness of the test specimen to the nearest <NUM>. In like fashion, repeat for a total of ten replicate test specimens. Calculate the arithmetic mean for all thickness measurements and report as Thickness to the nearest <NUM>.

Claim 1:
A disposable absorbent article having a longitudinal centerline and a lateral centerline generally perpendicular to the longitudinal centerline, first and second side edges and first and second end edges disposed at a first end and a second end of the absorbent article, respectively, the absorbent article further comprising:
a topsheet;
a backsheet;
an absorbent system disposed between the topsheet and the backsheet; and
a visual signal visible from a wearer-facing surface of the disposable absorbent article, wherein a difference between a length of the disposable absorbent article and a length of the visual signal is less than <NUM> as determined by the Article Length & Length of Visual Signal method;
wherein the absorbent article exhibits a performance factor of between <NUM> and <NUM>;
wherein the performance factor is the difference between the article length and visual signal length divided by the measured caliper as determined by the Article Length & Length of Visual Signal and Caliper methods as described herein .