Patent Description:
Absorbent articles are widely used to receive and store liquid contaminants for disposal. Commonly known absorbent articles include diapers, pull-on, pant-type diapers, adult incontinence articles, sanitary napkins, and panty liners. To effectively contain bodily exudates, the article should provide a snug fit around the waist and legs of a wearer.

It is not uncommon for absorbent articles to include elastic areas such as an elastic waist region and extensible ears to control the movement of liquids and provide a comfortable, conforming fit when the article is worn by a wearer.

Some absorbent articles such as diapers are manufactured to include back ears. For example, some varieties of diapers are manufactured with a pair of oppositely-oriented side back ears, extending laterally from each side of a back waist region of the diaper chassis, each back ear having a fastener located at or near the outboard edge thereof, and adapted to attach or adhere to a fastener receiving zone ("landing zone") disposed on a front waist region of the chassis. When the diaper is applied, back ears may traverse at least part of a high motion hip region of a wearer, therefore, extensible back ears are preferred over back ears without extensibility. Provision of extensibility on a diaper along a waist circumference using extensible back ears may be preferred as back ears are not constrained at application by a wearer laying on it while back waistband is. When the diaper is applied, each back ear may be in direct contact with the wearer's skin at a hip, therefore, extensible back ears having low roughness for being soft and gentle to the skin are preferred.

In some diapers, the back ears are formed at least in part of a laminate of one or more layers of nonwoven web and one or more layers or strands of a polymeric elastic material, and fashioned and adapted in such a way as to be elastically extensible in at least the direction in which the back ear is to be pulled during application and use. When worn, the back ears extend the diaper about the hip and waist of the wearer to anchor the diaper in use while still allowing the wearer to move comfortably. A fastening system is typically joined to the back ear to further secure the absorbent article about the wearer. Such laminates are for example disclosed in <CIT> and <CIT>.

Elastic laminates suitable for extensible back ears may be produced by methods well known in the industry. For example, elastic laminates may be produced by joining one or more nonwoven layers and an elastic material at approximately zero relative strain where the nonwoven layer(s) and the elastic material may be bonded using adhesive. The nonwoven layer(s) and the elastic material may be bonded by one or more elastic layers being extruded directly on to at least one nonwoven layer.

There have been many absorbent articles employing high modulus back ears to maximize a sustained fit and minimize leakage of bodily exudates. High modulus back ears require users to use a relatively high force to extend the back ears and low force users may not be able to achieve a good sustained fit and minimal leakage with a product comprising high modulus back ears.

Some absorbent articles comprise back ears having low modulus stretch. Low modulus stretch may be achieved by utilizing strands of elastomeric material. Elastic strands may provide less elastomeric material per cross-sectional area of the back ear, and require less force to extend. Elastic strands when used to produce elastic materials such as stranded laminates, however, do not create a uniform and even surface. Additionally, stranded laminates may have large surface gathers due to its bonding structure. Non-uniform surfaces and large surface gathers may cause skin marking and irritation when worn by a wearer. Non-uniform surfaces and large surface gathers may also be perceived as the product using the material is less holistically designed or has lower quality.

Meanwhile, the presence of multiple components in an absorbent article may not be favored by users in view of holistic product perception.

Therefore, it is desirable to provide absorbent articles with back ears having an appropriately designed stretch engine for users to use the stretch during diaper application to achieve better fit and sizing.

It is also desirable to provide absorbent articles with back ears having a more even surface and reducing the risk of skin marking when worn by a wearer.

It is also desirable to provide absorbent articles having holistic integrated perception.

The present invention relates to an absorbent article comprising a liquid pervious topsheet, a liquid impervious backsheet, an absorbent core disposed between the topsheet and backsheet; a first and a second opposing longitudinal side edges, a front waist region and a back waist region; a first and second back ear extending outwardly from the first and longitudinal side edges in the back waist region, respectively.

The first and second back ears comprise an elastomeric laminate comprising an elastomeric film, wherein the laminate is either an extrusion-bonded laminate or an ultrasonically-bonded laminate, and wherein the laminate does not include glue.

Each of the first and second back ears has an engineering strain greater than <NUM>% at 2N of force when measured according to the Back Ear Extension Test.

Each of the first and second back ears has an engineering strain less than about <NUM>% at 4N of force when measured according to the Back Ear Extension Test.

Preferred features of the invention are further described in the attached claims. Preferably, each of the first and second back ears have a roughness Ra lower than <NUM> when measured according to the Roughness Test. Each of the first and second back ears may have about <NUM>%- about <NUM>% of a 4hr growth when measured according to the 4hr Growth Test.

In the drawings, like numerals or other designations designate like features throughout the views.

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 an absorbent article comprising back ears having unique engineering strain properties and low surface roughness. One or more examples of these non-limiting embodiments are illustrated in the accompanying drawings. Those ordinary skilled in the art will understand that the absorbent articles 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, the term "absorbent article" refers to disposable devices such as infant, child, or adult diapers, adult incontinence products, training pants, sanitary napkins and the like which are placed against or in proximity to a body of a wearer to absorb and contain the various fluids (urine, menses, and/or runny BM) or bodily exudates (generally solid BM) discharged from the body. Typically, these absorbent articles comprise a topsheet, backsheet, an absorbent core, leg cuffs, optionally an acquisition system and/or a distribution system (which may be comprised of one or several layers), and typically other components, with the absorbent core normally placed at least partially between the backsheet and the acquisition and/or distribution system or between the topsheet and the backsheet. The absorbent articles comprising back ears having unique engineering strain properties and low surface roughness will be further illustrated in the below description and in the Figures in the form of one or more components of taped diaper. Nothing in this description should be, however, considered limiting the scope of the claims. As such the present disclosure applies to any suitable form of absorbent articles (e.g., diapers, training pants, adult incontinence products, sanitary napkins).

"Elastic," "elastomeric," and "elastically extensible" mean the ability of a material to stretch by at least <NUM>% without rupture or breakage at a given load, and upon release of the load the elastic material or component exhibits at least <NUM>% recovery (i.e., has less than <NUM>% set).

As used herein, the term "extensible" refers to the property of a material, wherein: when a biasing force is applied to the material, the material can be extended to an elongated length of at least <NUM>% of its original relaxed length (i.e. can extend <NUM>%), without a rupture or breakage that renders the material unusable for its intended purpose. A material that does not meet this definition is considered inextensible. In some embodiments, an extensible material may be able to be extended to an elongated length of <NUM>% or more of its original relaxed length without rupture or breakage that renders the material unusable for its intended purpose. An extensible material may or may not exhibit recovery after application of a biasing force.

As used herein, the term "film" means a sheet-like material wherein the length and width of the material far exceed the thickness of the material (e.g., 10x, 50x, or even 1000x or more). Films are typically liquid impermeable but may be configured to be breathable.

As used herein, "inboard", and forms thereof, with respect to features of a back ear, means furthest from or in a direction away from the free distal end.

As used herein, the term "joined", "bonded", or "attached" 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.

As used herein, the term "Junction line," with respect to a back ear comprising components that are discrete from other components of an absorbent article, which back ear is welded, bonded, adhered or otherwise attached to the absorbent article, referring to <FIG>, means a longitudinal line <NUM>, parallel with a longitudinal axis <NUM> of the absorbent article <NUM>, through the outboard-most point in a chassis attachment bond <NUM> at which the back ear is bonded to the chassis. Note: In some examples of back ears, the back ear is bonded to the chassis to have an irregular shape or orientation; in such examples, the point at which such shape or orientation are closest to an outboard edge of the back ear will mark the location of the junction line. "Junction line," with respect to a back ear comprising one or more components that are not discrete from, but rather, integral with, one or more components of a diaper chassis that is disposed in an opened, extended position and laid flat and horizontally, viewed from above, referring to <FIG>, means a line <NUM> parallel to the longitudinal axis <NUM> through the edge of the chassis <NUM> at its narrowest point <NUM>.

As used herein, the term "lateral" (and forms thereof), with respect to a line lying in a plane substantially occupied by an absorbent article back ear laid flat and horizontally, viewed from above, relates to a direction substantially perpendicular to a longitudinal axis of the absorbent article. "Lateral" and "width" (and forms thereof), with respect to features of an absorbent article back ear, relates to a direction, or generally following a direction, partially or entirely perpendicular to a longitudinal axis along the absorbent article. "Lateral" and "width" (and forms thereof), with respect to features of a diaper chassis, relates to a direction substantially parallel to the lateral axis of the chassis.

As used herein, the term "lateral axis" with respect to an absorbent article adapted to be worn by a wearer, means an axis perpendicular to the longitudinal axis, and equally dividing the longitudinal length of the article.

As used herein, the term "longitudinal" and "length" (and forms thereof), with respect to a line lying in a plane substantially occupied by an absorbent article back ear laid flat and horizontally, viewed from above, relates to a direction approximately aligned with the wearer's spine when the article would be normally worn, with the wearer in a standing or extended reclining position. "Longitudinal" and "length" (and forms thereof), with respect to features of a back ear, relates to a direction, or generally following a direction approximately aligned with the wearer's spine when the article would be normally worn, with the wearer in a standing or extended reclining position. "Longitudinal" and "length" (and forms thereof), with respect to features of a diaper chassis, relates to a direction approximately aligned with the wearer's spine when the article would be normally worn, with the wearer in a standing or extended reclining position.

As used herein, the term "longitudinal axis" with respect to an absorbent article adapted to be worn by a wearer, means an axis approximately aligned with the wearer's spine when the article would be normally worn, with the wearer in a standing or extended reclining position, and equally dividing the lateral width of the article, the lateral width being measured along a direction generally, parallel to the lateral axis.

As used herein, the term "nonwoven" means a porous, fibrous material made from continuous (long) filaments (fibers) and/or discontinuous (short) filaments (fibers) by processes such as, for example, spunbonding, meltblowing, airlaying, carding, coforming, hydroentangling, and the like. Nonwovens do not have a woven or knitted filament pattern. Nonwovens may be liquid permeable or impermeable.

As used herein, the term "outboard", and forms thereof, with respect to features of a fastening member, means at or in a direction toward its free distal end.

Where features or elements of claims set forth herein are identified as "lines" or "line segments" or "points", such lines, line segments or points are not actual physical features themselves unless otherwise specified, but rather, are geometric references intended for use in describing locations on a physical structure.

Referring to <FIG>, a diaper <NUM>, an example of absorbent articles, comprises a chassis comprising a liquid pervious topsheet <NUM>, a liquid impervious backsheet <NUM> and an absorbent core <NUM> disposed between the topsheet <NUM> and backsheet <NUM>. The garment-facing surface <NUM> of the diaper <NUM> is facing the viewer. The diaper <NUM> includes a longitudinal centerline <NUM> and a lateral centerline <NUM>. The diaper <NUM> includes a front waist region <NUM>, a back waist region <NUM> opposed to the front waist region <NUM>, and a crotch region <NUM> located between the front waist region <NUM> and the back waist region <NUM>. The waist regions <NUM>, <NUM> generally comprise those portions of the diaper <NUM> which, when worn, encircle the waist of the wearer. The waist regions <NUM> and <NUM> may include an elastic element that may gather or allow the material to extend in the front and/or back waist region <NUM>, <NUM> about the waist of the wearer to provide improved fit and containment. The crotch region <NUM> is that portion of the diaper <NUM> which, when the diaper <NUM> is worn, is generally positioned between the legs of the wearer. The outer periphery of the diaper <NUM> is defined by longitudinal side edges <NUM> and end edges <NUM>. The opposing longitudinal side edges <NUM> may be oriented generally parallel to the longitudinal centerline <NUM>. Elastic elements may be disposed adjacent the side edges <NUM> of the diaper <NUM> to form gasket cuffs when the diaper <NUM> is in a fastened configuration.

The diaper <NUM> shown in <FIG> includes a liquid permeable topsheet <NUM>, a liquid impermeable backsheet <NUM>, and an absorbent core <NUM> disposed therebetween. The absorbent core <NUM> may have a body-facing surface and a garment facing-surface. The topsheet <NUM>, the backsheet <NUM>, and the absorbent core <NUM> may be assembled in a variety of well-known configurations. For example, the topsheet <NUM> may be joined to the core <NUM> and/or the backsheet <NUM>. The backsheet <NUM> may be joined to the core <NUM> and/or the topsheet <NUM>. It should be recognized that other structures, elements, or substrates may also be positioned in a joined or unjoined relationship between the core <NUM>, the topsheet <NUM> and/or the backsheet <NUM>. Nonlimiting examples of suitable diaper configurations are described generally in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>; and <CIT>.

The topsheet <NUM> typically includes a portion of the diaper <NUM> that is positioned at least in partial contact or close proximity to a wearer. Suitable topsheets <NUM> may be manufactured from a wide range of materials, such as porous foams; reticulated foams; apertured films; or woven or nonwoven web of natural fibers (e.g., wood or cotton fibers), synthetic fibers, or a combination of natural and synthetic fibers; or multilayer laminates of these materials. Generally, at least a portion of the topsheet <NUM> is liquid pervious, permitting liquid to readily penetrate through the thickness of the topsheet <NUM>. Any portion of the topsheet <NUM> may be coated with a lotion as is known in the art. Examples of suitable lotions include those described in <CIT>; <CIT>; <CIT>; and <CIT>.

The absorbent core <NUM> may comprise a wide variety of liquid-absorbent materials commonly used in disposable diapers and other absorbent articles (e.g., superabsorbent polymer particles ("SAP") and/or airfelt). These materials may be combined to provide a core <NUM> in the form of one or more layers, which may include fluid handling layers such as acquisition layers, distribution layers and storage layers. Such absorbent cores <NUM> may also include layers to stabilize other core components. Such layers may include a core cover and a dusting layer. In certain embodiments, the absorbent core <NUM> may include less than <NUM> wt% of airfelt, based on weight of the absorbent core <NUM>, or the absorbent core <NUM> may even be airfelt-free. Exemplary absorbent structures for use as the absorbent core <NUM> are described in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>; <CIT>; and <CIT>.

The backsheet <NUM> may be positioned such that it includes at least a portion of the garment-facing surface <NUM> of the diaper <NUM>. The backsheet <NUM> may be designed to prevent the exudates absorbed by and contained within the diaper <NUM> from soiling articles that may contact the diaper <NUM>, such as bed sheets and undergarments. In certain embodiments, the backsheet <NUM> is substantially water-impermeable. One suitable backsheet <NUM> materials may include breathable materials that permit vapors to escape from the diaper <NUM> while still preventing exudates from passing through the backsheet <NUM>. Such breathable composite materials are described in greater detail in <CIT> and <CIT>. Other breathable backsheets including nonwoven webs and apertured formed films are described in <CIT>. An exemplary, suitable backsheet is disclosed in <CIT>. Other suitable materials and/or manufacturing techniques may be used to provide a suitable backsheet <NUM> including, but not limited to, surface treatments, particular film selections and processing, particular filament selections and processing, etc..

The backsheet <NUM> may also include more than one layer configured, for example, as discrete, unjoined layers or as laminate. It is to be appreciated that such laminate structures are not limited to the backsheet <NUM>, but may be incorporated into any of the diaper <NUM> components described herein or commonly known in the art (e.g., ears or sides panels), as desired.

The diaper <NUM> may also include a fastening system <NUM>. When fastened, the fastening system <NUM> typically interconnects the front waist region <NUM> and the back waist region <NUM> resulting in a waist circumference that generally encircles a wearer of the diaper <NUM>. Exemplary surface fastening systems are disclosed in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>. An exemplary interlocking fastening system is disclosed in <CIT>. The fastening system <NUM> may also provide a means for holding the article in a disposal configuration as disclosed in <CIT>. The fastening system <NUM> may also include primary and secondary fastening systems, as disclosed in <CIT>. The fastening system <NUM> may be constructed to reduce shifting of overlapped portions or to improve fit as disclosed in <CIT>; <CIT>; <CIT>; and <CIT>.

In certain embodiments, a portion of the fastening system <NUM> may be disposed on one or more ears, including for example front ears <NUM> disposed in the front waist regions and/or back ears <NUM> disposed in the back waist region. For example, the fastening system <NUM> exemplified in <FIG>, which includes a fastening member <NUM> and a landing zone <NUM>, may be configured with the fastening member <NUM> disposed on the back ear <NUM>. The fastening member <NUM> includes a fastener <NUM> that is engageable with a complementary receiving surface on the landing zone <NUM> and/or another portion of the diaper <NUM>. In certain embodiments, the fastening member <NUM> may be an integral part of the back ear <NUM>. When fastened, the fastening member <NUM> interconnects the front waist region <NUM> and the back waist region <NUM> resulting in a waist circumference that may encircle the wearer during wear of the absorbent diaper <NUM>. The fastening member <NUM> may comprise a fastener <NUM> such as adhesives, hook and loop fastening components, interlocking fasteners such as tabs & slots, buckles, buttons, snaps, and/or hermaphroditic fastening components, although any other known fastening means are generally acceptable. An engagement element <NUM> also may include groups of separately identifiable fastening elements such as a plurality of discrete patches of adhesive-bearing material, discrete patches of hooks, etc..

The fastening system <NUM> may further comprise a landing zone to which a fastener can engage and/or a release tape that protects the fastening elements from insult prior to use. Some exemplary surface fastening systems are disclosed in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>. An exemplary interlocking fastening system is disclosed in <CIT>. In some embodiments, the fastening member <NUM> is foldable.

The fastening member <NUM> may be joined to any suitable portion of the diaper <NUM> by any suitable means. In some embodiments, the fastening member <NUM> is joined to the ear. The fastening member may be joined to the ear between layers. The fastening member may be joined to the ear on an exterior surface. In one nonlimiting example, the fastening member <NUM> and/or fastener <NUM> are mechanically bonded to the ear.

The diaper <NUM> may include one or more ears <NUM>, <NUM>, which extend laterally outwardly from one or both side edges <NUM> in the front and/or back waist regions <NUM>, <NUM>. Front ears <NUM> and/or back ears <NUM> may extend in the longitudinal direction from the end edge <NUM> of the diaper <NUM> to the portion of the side edge <NUM> of the diaper <NUM> that forms the leg openings when the diaper <NUM> is in a fastened configuration. The front ears <NUM> or the back ears <NUM> may be discrete components from other components of the diaper <NUM>. For example, back ears <NUM> are welded, bonded, adhered or otherwise attached via a chassis attachment bond <NUM> to the diaper <NUM>. The front ears <NUM> or the back ears <NUM> may be integral with a chassis component forming an extension thereof such that the front ears <NUM> or the back ears <NUM> may be configured as unitary elements of the backsheet, topsheet, core and/or another component in the chassis (i.e., they are formed from and are extensions of the backsheet, topsheet, core and/or the component materials), or the front ears <NUM> or the back ears <NUM> may be discrete component affixed to portions of chassis by any suitable means known in the art.

One or more of ears <NUM> may be extensible or elastic. Ears <NUM> may be formed from one or more nonwoven webs, woven webs, knitted fabrics, polymeric and elastomeric films, apertured films, sponges, foams, scrims, elastic strands, elastic nonwovens or combinations and/or laminates of any the foregoing. The first and second back ears comprise a laminate comprising an elastomeric film, wherein the laminate is either an extrusion-bonded laminate or an ultrasonically-bonded laminate, and wherein the laminate does not include glue.

<FIG> illustrates a discrete back ear. Back ear <NUM> may include an outboard edge <NUM> and an inboard edge <NUM>. The outboard edge <NUM> is the free distal longitudinal edge of the ear when said ear is joined to the chassis. The inboard edge <NUM> is substantially opposed to the outboard edge and is joined to or overlapped with the chassis when the ear is joined to the chassis. Ears may further include a first lateral edge <NUM> and an opposing second lateral edge <NUM>.

The first and second back ears comprise an elastomeric film. In certain embodiments, back ear <NUM> may be formed of a stretch laminate such as a nonwoven/elastomeric material laminate or a nonwoven/elastomeric material/nonwoven laminate, which also results in the ear being extensible. Back ear <NUM> may be extensible laterally. In some embodiments, the back ear <NUM> is also extensible longitudinally.

In some embodiments, referring to <FIG>, one or more of the ears <NUM>, <NUM>, especially back ear <NUM>, comprises a first nonwoven layer <NUM>, a second nonwoven layer <NUM> and an elastomeric layer <NUM>. The elastomeric layer <NUM> may be sandwiched between the first and second nonwovens. The elastomeric layer <NUM> may be the same size as the first and second nonwoven layers <NUM>, <NUM>. The elastomeric layer <NUM> may be a smaller size than the first and second nonwoven layers <NUM>, <NUM>. The first nonwoven layer <NUM> may be formed by the same or different nonwoven material from the second nonwoven layer <NUM>. The back ear may include at least one additional layer comprising, for example, nonwoven, an inelastic material, elastic or extensible material, etc..

Any suitable nonwoven may be used in one or more of the ears <NUM>, <NUM>. Suitable nonwoven webs can be formed by direct extrusion processes during which the fibers and webs are formed at about the same point in time, or by preformed fibers which can be laid into webs at a distinctly subsequent point in time. Example direct extrusion processes include but are not limited to: spunbonding, meltblowing, solvent spinning, electrospinning, and combinations thereof typically forming layers.

Example of nonwoven combination includes but are not limited to spunbond-meltblown-spunbond (SMS), spunbond-carded (SC), spunbond-airlaid (SA), meltblown-airlaid (MA), and combinations thereof, typically in layers. Combinations which include direct extrusion can be combined at about the same point in time as the direct extrusion process (e.g., spinform and coform for SA and MA), or at a subsequent point in time. In the above examples, one or more individual layers can be created by each process. For instance, SMS can mean a three layer, 'sms' web, a five layer 'ssmms' web, or any reasonable variation thereof wherein the lower case letters designate individual layers and the upper case letters designate the compilation of similar, adjacent layers. The fibers in a nonwoven web are typically joined to one or more adjacent fibers at some of the overlapping junctions. This includes joining fibers within each layer and joining fibers between layers when there is more than one layer. Fibers can be joined by mechanical entanglement, by chemical bond, ultrasonic bond, mechanical pressure bonds, thermal bonds, or adhesives or by combinations thereof.

In some embodiments, nonwoven fabric can be unbonded nonwoven webs, electrospun nonwoven webs, flashspun nonwoven webs (e.g., TYVEKTM by DuPont), or combinations thereof. These fabrics can comprise fibers of polyolefins such as polypropylene or polyethylene, polyesters, polyamides, polyurethanes, elastomers, rayon, cellulose, copolymers thereof, or blends thereof or mixtures thereof. The nonwoven fabrics can also comprise fibers that are homogenous structures or comprise bicomponent structures such as sheath/core, side-by-side, islands-in-the-sea, and other bicomponent configurations. For a detailed description of some nonwovens, see "Nonwoven Fabric Primer and Reference Sampler" by E. Vaughn, Association of the Nonwoven Fabrics Indus-3d Edition (<NUM>).

In one approach, nonwoven web can be made of bi-component or multi-component fibers. One of the components of the fibers, preferably outer component, is soft polymer such as polyethylene or elastic polyolefin, polyurethane. For example, in sheath/core bi-component fiber, sheath can be made of polyethylene while core can be made of polypropylene.

In another approach, nonwoven web can be made of mono-component fiber. However, fiber is made of polymer blend to impart silky soft feel. For example, polypropylene nonwoven can be coarse. However, when blended with elastomeric polypropylene (VISTAMAXX® from Exxon), it can help improve the feel of the fiber.

In another approach, nonwoven web can be made of elastomeric polymer. For example, elastomeric polyolefins are used in fibers spinning and to make nonwoven web. Such webs have very sleek feel, and elastic properties, that is often desired for consumer products.

In another approach, additives can be added to polymer before spinning fiber. During fiber spinning and subsequent process steps to make nonwoven web, the additives migrate to fiber surface to provide silky feel. Amine and Amide based additives are commonly used up to <NUM>% to impart softness.

In another approach, sleek chemical finish can be coated on the fibers or nonwoven webs. Chemical finishes based on oil, silicone, esters, fatty acids, surfactant etc. can be employed. Softeners such as anionic, cationic or nonionic can also be used to improve drape, and touch. Various coating techniques, like roll coating, screen coating, gravure coating, slot coating, spray coating, can be used to apply finish.

In another approach, nonwoven fiber diameter can be reduced to produce fine fibers and to provide silk like feel. Meltblown fiber is one technology to reduce fiber diameter to less than <NUM> microns. Alternatively, nanofibers, having a diameter of less than <NUM> micron, made from a melt film fibrillation process with a polymer composition disclosed in <CIT> patent can be used to provide softness.

In nonlimiting examples, a nonwoven comprises a meltblown layer. Additionally or alternatively, a nonwoven may comprise spunbond layers. In a nonlimiting example, a nonwoven comprises two or more spunbond layers. In further nonlimiting examples, one or more nonwovens may comprise a SMS configuration. Alternatively, one or more of the nonwovens in the ear may be void of meltblown layers. While meltblown layers have been found to enhance bonding in ears requiring adhesive (given the meltblown layer's inhibition of the adhesive's diffusion through the porous nonwoven structure), meltblown layers often lack strength. In some embodiments, a nonwoven consists essentially of spunbond layers. In some nonlimiting examples, both the first and the second nonwoven comprises at least <NUM> spunbond layers, or <NUM> or more spunbond layers.

Where one or more of the ears <NUM>, <NUM> comprise more than one nonwoven, the nonwovens may comprise the same basis weight or different basis weights. Likewise, the nonwovens may comprise the same layer structure or different layer structures. Further, a nonwoven in the ear may comprise the same or different features of nonwovens in the backsheet, topsheet, leg gasketing system and/or waist feature.

The elastomeric layer <NUM> comprises an elastomeric film (e.g., polyurethane films, films derived from rubber and/or other polymeric materials). Elastomeric materials can be formed from elastomeric polymers including polymers comprising styrene derivatives, polyesters, polyurethanes, polyether amides, polyolefins, polyvinyl chloride, combinations thereof or any suitable known elastomers. Exemplary elastomers and/or elastomeric materials are disclosed in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT> and <CIT>. Commercially available elastomeric materials include KRATON (styrenic block copolymer; available from the Kraton Chemical Company, Houston, TX), SEPTON (styrenic block copolymer; available from Kuraray America, Inc. , New York, NY), VECTOR (styrenic block copolymer; available from TSRC Dexco Chemical Company, Houston, TX), ESTANE (polyurethane; available from Lubrizol, Inc, Ohio), PEBAX (polyether block amide; available from Arkema Chemicals, USA), HYTREL (polyester; available from DuPont, USA), VISTAMAXX (homopolyolefins and random copolymers, and blends of random copolymers, available from EXXON Mobile, USA), and VERSIFY (homopolyolefins and random copolymers, and blends of random copolymers, available from Dow Chemical Company, USA).

The elastomeric film may comprise a single layer or multiple layers. The film may be elastic in the lateral direction. The elastomeric layer <NUM> may comprise a width, Y, as shown for example in <FIG>. In some embodiments, Y is less than the width, W, of the back ear <NUM> by at least about <NUM>. The elastomeric layer <NUM> may have a longitudinal dimension that is the same as the back ear <NUM> along with the width Y of the elastomeric layer <NUM>, or a longitudinal dimension that is less than the longitudinal length of the ear at any point along with the width of the elastomeric layer. In some embodiments, the elastomeric layer may have a basis weight of from about <NUM> to about 150gsm, or from about <NUM> to about 100gsm, or less than about 150gsm, reciting for each range every 5gsm increment therein.

As also illustrated in <FIG>, the back ear <NUM> comprises an elastic region <NUM>. The elastic region <NUM> is generally defined by the perimeter of an area elastically extensible in the elastomeric layer <NUM>. In case the elastomeric layer <NUM> has an inextensible area at any edge in the width direction, the width, WE, of the elastic region <NUM> is shorter than the width, Y, of the elastomeric layer <NUM>. In some embodiments, the area of the elastic region comprises at least about <NUM>% of, or from about <NUM>% to about <NUM>% of the total area of the ear, reciting for said range every <NUM>% increment therein. In further embodiments, Y (i.e., the maximum width of the elastomeric layer <NUM>) is at least about <NUM>% of, or from about <NUM>% to about <NUM>%, or from about <NUM>% to about <NUM>% of the total width, W, of the back ear <NUM>, reciting for each range every <NUM>% increment therein. The back ear <NUM> may further comprise one or more inelastic regions. In certain embodiments, the back ear <NUM> comprises a first inelastic region <NUM>, which extends laterally outward from the inboard edge <NUM> and is adjacent to the elastic region <NUM> at an inboard edge <NUM> of the elastic region <NUM>. The ear may further include a second inelastic region <NUM>, which may extend laterally inward from the outboard edge <NUM> and may be adjacent to outboard edge <NUM> of the elastic region <NUM>. The first and second inelastic regions may be made of the same material(s) or different materials. Referring to <FIG>, the length of a fastener <NUM> inboard edge is shown as LFP, and the length of an inboard edge <NUM> of the elastic region <NUM> is shown as LEP. In an embodiment wherein an back ear <NUM> has an elastic region <NUM> with no inelastic region, LEP is the length of inboard edge <NUM> of the back ear <NUM>.

Still referring to <FIG>, a reference width WS can be identified, as the width from the junction line <NUM> to an inboard edge <NUM> of the fastener <NUM>. In some examples, the fastener <NUM> may have an irregular shape or orientation, or consist of a plurality of engaging portions; in such examples, the point at which such shape, orientation or extensible portions are closest to a longitudinal axis of an absorbent article is considered the inboard edge <NUM> of the fastener <NUM>.

In certain embodiments, the back ear <NUM> comprises a laminate comprising multiple layers, wherein one of the layers is strained to a greater degree than a remaining layer during lamination. In this way, the less extensible layer, the nonwoven <NUM>, <NUM> in case of <FIG>, will form gathers when the laminate is in a relaxed state. In some embodiments, the elastomeric layer is strained while the nonwoven(s) are in a relaxed state during lamination. The elastomeric layer may be stretched one or more directions. Corrugations then may form in the nonwoven layer(s) when the subsequently formed laminate is in a relaxed state. Non-limiting examples of the laminating suitable for the present invention include an extrusion bonded laminate and an ultrasonically bonded laminate. Extrusion bonded laminates may be produced according to a conventional extrusion bonded laminate production process by extruding a molten film directly on to a carrier such as a nonwoven. An ultrasonically bonded laminate may be produced by the process and/or equipment disclosed in <CIT>. It is to be appreciated that ultrasonically bonded elastic laminates may include various portions of components bonded together in various ways and with bonds having differing or identical bond patterns. Non-limiting examples of ultrasonically bonded laminates comprising a bond pattern include those disclosed in <CIT>.

A laminate useful for the present invention may further comprise a reinforcement layer to improve strength of the laminate. Non-limiting examples of such laminates are disclosed in <CIT>.

The laminate useful for the present invention is produced without using glue. Laminates with substantially no glue may be preferable with respect to lower potential malodor issue, production cost, process complexity and process contamination with glue. In other embodiments, the laminate for the present invention is a non-activated laminate produced without conducting a laminate activation step. "Activated" or "activation", when used relative a laminate for a back ear herein, means the mechanical deformation of a plastically extensible laminate that results in permanent elongation of the laminate, in the direction of activation in the X-Y plane of the laminate. For example, activation occurs when a laminate is subjected to a stress that causes the laminate to strain beyond the onset of plasticity, which may or may not include complete mechanical failure of the laminate or a portion of laminate. Activation of a laminate that includes an elastic material joined to a plastically extensible material typically results in permanent deformation of the plastic material, while the elastic material returns substantially to its original dimension. Activation processes include incremental stretching and SELFing. "Incremental stretching" means a process in which a web material is controllably plastically stretched in increments along one or more directions by being passed under tension between the surfaces of a pair of stretching members having continuously intermeshing ridges and valleys, or other intermeshing features as described for example, in <CIT> and <CIT>. Ring-rolling is a type of incremental stretching. "SELF" or "structured elastic-like film" means a process in which a web material is controllably plastically stretched in increments along one or more directions by being passed under tension between the surfaces of a pair of stretching members having discontinuously intermeshing ridges and valleys, or other features as described in, for example, <CIT>.

In another method, elastic laminates may be consolidated or pre-contracted laminates where an elastic material is strained prior to being bonded to a nonwoven layer. The elastic material, for example when it is film may be pre-activated before being laminated with nonwoven layer(s) to create a plurality of cracks and tears in the skins at a microscopic scale. In turn, these cracks and tears may help reduce the skin contribution to the extension forces. Pre-activation of film may be performed by for example, a process disclosed in <CIT>.

In nonlimiting examples, the elastomeric layer is stretched in a direction corresponding with the lateral direction of the article. In other words, when the ear is joined to the chassis subsequent to lamination, the ear laminate will be oriented such that the ear is stretchable in the lateral direction of the article. In further nonlimiting examples, the ear is also stretchable in the longitudinal direction.

Back ear <NUM> may be attached to an absorbent article in any suitable manner, including, but not limited to, continuous or intermittent adhesive bonding, compression bonding, heat bonding, ultrasonic bonding, etc..

Back ears in absorbent articles according to the present invention have an engineering strain equal to or greater than about <NUM>%, or greater than about <NUM>% at about or below 2N of force when measured according to the Back Ear Extension Test. It was noticed that some users tend not to fully utilize the extension property of the back ear which results in poor sustained fit and a potential leakage problem. An engineering strain at about or below 2N may be meaningful as 2N is considered an average force some users initially apply on diaper when the users apply diapers on wearers. When the back ears have an engineering strain lower than <NUM>% at about or below 2N, users may perceive the back ears do not provide enough extensibility. In some embodiments, a back ear extends at least about <NUM> at about or below 2N of force measured according to the Back Ear Extension Test described later. The at least about <NUM> extensibility at about or below 2N may communicate noticeable extensibility of the back ear.

Back ears in absorbent articles according to the present invention have an engineering strain less than about <NUM>%, or less than about <NUM>% at about or below 4N of force when measured according to the Back Ear Extension Test described later. If the force to extend a back ear does not increase sufficiently such that the back ear extends more than <NUM>% at 4N, users may perceive the absorbent article is low quality, or that the back ears are weak and may break during use. Additionally, back ears that extend more than <NUM>% at 4N may lead to poor sustained fit, increased sagging, and leakage. An engineering strain at about or above 4N may be meaningful as 4N is considered almost the maximum force some users apply on diaper when the users apply diapers on wearers.

Back ears in absorbent articles according to the present invention have a roughness Ra equal to or lower than <NUM>, equal to or lower than <NUM>, or equal to or lower than about <NUM> when measured according to the Roughness Test. When the roughness of a back ear is higher than about <NUM>, it may be perceived or felt the back ear is harsh and is not gentle to the skin.

Back ears in absorbent articles according to the present invention may have a 4hr growth in the range of 1d% - <NUM>%, <NUM>% - <NUM>%, or <NUM>% - <NUM>% when measured according to the 4hr Growth Test. When the 4hr growth(%) of a back ear is lower than <NUM>%, <NUM>% or lower than <NUM>%, the diaper having the back ears may be less prone to slip or sag about a wearer.

For the purposes of providing holistic material integrity, the back ears in use status may have <NUM>% of opacity, or <NUM>% of opacity.

As noted in the Background, back ears of a diaper may be designed and situated to wrap around a wearer's hips. As a result, they may be in contact with the skin at the wearer's hips while the diaper is being worn. Additionally, while a diaper is being worn the back ears will sustain and transfer varying tension forces, particularly when the wearer is active and bending at the hips. These tension forces have normal force components acting on the wearer's skin. Thus, it may be desirable that the material forming the skin-contacting portions of a back ear <NUM> be selected with the objectives of appropriately designed extensibility, pliability and an even surface area. Increasing these variables generally may help to provide for sustained fit, improve undesired sag and/or leakage of bodily exudates, and reduce the likelihood of skin marking and chafing.

An engineering strain and an extension of a back ear specimen is measured using a constant rate of extension tensile tester with computer interface such as MTS Alliance under Test Works <NUM> software (MTS Systems Corp. , USA) fitted with a suitable load cell. The load cell should be selected to operate within <NUM>% and <NUM>% of its stated maximum load. All testing is performed in a conditioned room maintained at about <NUM>±<NUM> and about <NUM>%±<NUM>% relative humidity. Herein, width and length of the specimen are a lateral width and longitudinal length as defined herein. Precondition specimens at about <NUM>±<NUM> and about <NUM>%±<NUM>% relative humidity for <NUM> hours prior to testing.

A 4hr growth of a back ear specimen is measured using a clamp affixed to a vertical stand, and an appropriate weight to deliver a total of <NUM>+/-1grams on the back ear specimen. The vertical stand and weight are configured such that when a back ear specimen is attached for testing, the back ear specimen can at least double in length, or at least increase in length by <NUM> (whichever is larger) without the weight contacting the table, floor, or base of the stand.

Opacity may be measured using a <NUM>° illumination / <NUM>° detection, circumferential optical geometry, spectrophotometer such as a Spectroguide <NUM> spectrophotometer (BKY Gardner, Germany). Instrument calibration and measurements are made using the standard white and black calibration plates provided by the vendor. All testing is performed in a room maintained at about <NUM>± <NUM> and about <NUM> ± <NUM> % relative humidity.

The spectrophotometer is configured for the XYZ color scale, D65 illuminant, <NUM>° standard observer, with UV filter set to nominal. The instrument is standardized according to the manufacturer's procedures using the <NUM> view area.

Back ear material <NUM> including a first nonwoven and second nonwoven, and an elastomeric film sandwiched between the first and second nonwoven was prepared. Each of the first and second nonwoven were 17gsm SMS available from Avgol, USA under tradename AVMN1048007001. The nonwovens had an average basis weight of <NUM>. <NUM> ± <NUM>. The elastomeric film was 40gsm X38824 available from Tredegar Corporation, USA. The film having a width of <NUM> in a relaxed condition was stretched to <NUM>% strain (i.e., <NUM> stretched to about <NUM>). In its stretched state, the width grew by about <NUM> due to set. While the film was stretched as described, the first and second nonwoven which were relaxed were ultrasonically bonded through the film the using the bonding pattern shown in <FIG> and an ultrasonic bond pressure of 400N.

CozyFlex 2711GV (Golden Phoenix Fiberwebs, USA), an extrusion bonded laminate of nonwoven and film, was used back ear material <NUM>.

Diapers having back ears formed by the back ear material <NUM> and back ear material <NUM> were prepared according to a conventional diaper production process.

Table <NUM> shows diaper samples having back ears from various extensible materials. Back ears were cut off from the diaper samples, and extensibility of each back ear at 2N and 4N, and 4hr growth (%) were measured according to the Back Ear Extension Test and 4hr Growth Test, respectively. In addition, roughness of each back ear was measured according to the Roughness Test. Opacity of back ears were also measured according to the Opacity Measurement. Results are shown in Table <NUM> below.

Fitness and stretchability of diapers were measured using characteristics including those specified in Table <NUM> with <NUM> panels who rated the intensity of the discrete product characteristics on a <NUM>-<NUM> using all their senses. Data is reported as means for the entire group. Results are shown in Table <NUM> below.

Claim 1:
An absorbent article (<NUM>) comprising:
a chassis comprising a liquid pervious topsheet (<NUM>), a liquid impervious backsheet (<NUM>), an absorbent core (<NUM>) disposed between the topsheet and backsheet;
a first and a second opposing longitudinal side edges, a front waist region (<NUM>) and a back waist region (<NUM>);
a first back ear (<NUM>) extending outwardly from the first longitudinal side edge in the back waist region;
a second back ear extending outwardly from the second longitudinal side edge in the back waist region;
wherein the first and second back ears comprise a laminate comprising an elastomeric film (<NUM>), wherein the laminate is either an extrusion-bonded laminate or an ultrasonically-bonded laminate, and wherein the laminate does not include glue,
wherein each of the first and second back ears has an engineering strain greater than <NUM>% at 2N of force when measured according to the Back Ear Extension Test,
wherein each of the first and second back ears has an engineering strain less than <NUM>% at 4N of force when measured according to the Back Ear Extension Test, and
wherein each of the first and second back ears have a roughness Ra lower than <NUM> when measured according to the Roughness Test.