Patent Description:
With respect to currently known product designs and the materials currently known and used as components of these products, these expectations and preferences cannot all be fully satisfied simultaneously. The manufacturer must carefully balance its priorities, to provide product features that address each of these expectations and preferences to greater and lesser extents under competitive cost/pricing constraints, in order to provide a product that will sufficiently please its user/consumer market. For example, absorbent materials that desirably provide absorption capacity also undesirably contribute to bulk when packaged and when worn under clothing, and may also limit flexibility of the pad. Accordingly, when designing its products for maximized consumer satisfaction, the manufacturer must make choices concerning how to prioritize design features and materials selections that affect these characteristics, to strike a balance that will hopefully maximize satisfaction of its consumer market.

Document <CIT> discloses a package for an individual absorbent article, in particular a sanitary napkin or panty liner, comprising a weakening line facilitating the opening of the package by a user. Hereby, the package can also be used as a waste pouch for a used sanitary napkin or panty liner.

Document <CIT> relates to a personal care article connected in facing relation with a wrap member. The article is folded about a first, laterally extending supplemental-fold-region and then the article and a corresponding section of the wrap member are folded about a second, laterally extending supplemental-fold-region.

Document <CIT> discloses a folded absorbent article for the absorption of body fluids, which is packaged in a packaging wrapper comprising a container part with an opening and a lid part. A distance element is arranged between the lid part and the container part to facilitate opening the packaging wrapper.

Document <CIT> relates to a personal care product including a wrapper having at least one free edge, an absorbent personal care article and a sensory cue providing indicia as to the location of the free edge. The wrapper may have a first panel and a second panel, which are both connected to a back panel and exhibit one or more different sensory attributes. This difference provides a contrast between the panels and an indicium as to the location of the free edge connecting the panels. The sensory cue can also be used to direct a user as to how to open the wrapper.

Consequently, there is always room for any improvements that can more satisfactorily and simultaneously address consumer preferences for convenience and discreetness of package carry, opening and access, combined with absorption performance.

The present invention relates to a product comprising a feminine hygiene pad in a folded configuration provided within an individualized envelope package according to the subject-matter of claim <NUM>.

With respect to a feminine hygiene pad that is open and laid out flat on a horizontal planar surface, "lateral" refers to a direction perpendicular to the longitudinal direction and parallel the horizontal planar surface. "Width" refers to a dimension measured along a lateral direction.

With respect to a feminine hygiene pad that is open and laid out flat on a horizontal planar surface and having a length measured from its forwardmost end to its rearwardmost end, "longitudinal" refers to a direction parallel with the line along which the length is measured, and parallel to the horizontal planar surface. "Length" refers to a dimension measured in the longitudinal direction.

With respect to a feminine hygiene pad, the terms "front," "rear," "forward" and "rearward" relate to features or regions of the pad in a position as it would ordinarily be worn by a user, and the front and rear of the user's body when standing.

With respect to a feminine hygiene pad that is open and laid out flat on a horizontal planar surface, "z-direction" refers to a direction perpendicular to the horizontal planar surface. When the pad is being worn by a user (and thus in a curved configuration), "z-direction" at any particular point location on the pad refers to a direction normal to the wearer-facing surface of the pad at the particular point location.

With respect to a feminine hygiene pad, "wearer-facing" is a relative locational term referring to a feature of a component or structure of the pad that when in use that lies closer to the wearer than another feature of the component or structure that lies along the same z-direction. For example, a topsheet has a wearer-facing surface that lies closer to the wearer than the opposite, outward-facing surface of the topsheet.

With respect to a feminine hygiene pad, "outward-facing" is a relative locational term referring to a feature of a component or structure of the pad that when in use that lies farther from the wearer than another feature of the component or structure that lies along the same z-direction. For example, a topsheet has an outward-facing surface that lies farther from the wearer than the opposite, wearer-facing surface of the topsheet.

Referring to <FIG> and <FIG>, a feminine hygiene pad <NUM> may include a liquid permeable topsheet <NUM>, a liquid impermeable backsheet <NUM> and an absorbent layer <NUM> disposed between the topsheet and the backsheet. The absorbent layer has an outer perimeter <NUM>. In peripheral regions outside the outer perimeter <NUM>, the topsheet and the backsheet may be bonded together in laminated fashion by any suitable mechanism including but not limited to adhesive bonding, thermal bonding, pressure bonding, etc., thereby retaining and holding the absorbent layer <NUM> in place between the topsheet <NUM> and the backsheet <NUM>. Pad <NUM> may include opposing wing portions <NUM> extending laterally outside of perimeter <NUM> by a comparatively greater width dimension than the main portion of the pad. Wing portions <NUM> may be formed of lateral extensions of the material forming the topsheet <NUM>, backsheet <NUM>, or both together. The outward-facing surface of the backsheet forming the undersides of the main portion and the wing portions may have deposits of adhesive <NUM> thereon. Adhesive deposits <NUM> may be provided to enable the user to adhere the pad to the inside of her underpants in the crotch region thereof, and wrap the wing portions through and around the inside edges of the leg openings of the underpants and adhere them to the outside/underside of the underpants in the crotch region, providing supplemental holding support and helping guard the leg edges of the underpants against soiling. When pad <NUM> is packaged, adhesive deposits <NUM> may be covered by one or more removable sheets of release film or paper (not shown) that cover the adhesive deposits <NUM> and shield them from contact with other surfaces until the user is ready to remove the sheets and place the pad for use.

To ensure that the pad facilitates sufficiently compact folding and packaging as described herein, it may be desired to limit the length LP of the pad to no greater than <NUM>, more preferably no greater than <NUM>, and even more preferably no greater than <NUM>. Alternatively, or in addition, it may be desired to limit the length LAL of the absorbent layer (also measured in the longitudinal direction) to no greater than <NUM>, more preferably no greater than <NUM>, and even more preferably no greater than <NUM>.

Topsheet <NUM> may be formed of any suitable liquid permeable web material. Referring back to the figures, the topsheet <NUM> is positioned adjacent a wearer-facing surface of the absorbent layer <NUM> and may be joined thereto and to the backsheet <NUM> by any suitable attachment or bonding method. The topsheet <NUM> and the backsheet <NUM> may be joined directly to each other in the peripheral regions outside the perimeter <NUM> of the absorbent layer <NUM> and may be indirectly joined by directly joining them respectively to wearer-facing and outward-facing surfaces of the absorbent layer or additional optional layers included with the pad.

Topsheet <NUM> may be formed of any liquid pervious web material that is suitably compliant, soft feeling, and non-irritating to the wearer's skin. Suitable topsheet materials include a liquid pervious material that contacts the body of the wearer and permits menstrual fluid discharges to rapidly penetrate through it.

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; hydro-formed 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 web materials that may be 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 examples, the topsheet may comprise tufts as described in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>. The topsheet may have a pattern of discrete hair-like fibrils as described in <CIT> or <CIT>. Additional examples of suitable topsheet materials include those described in <CIT>; <CIT>; <CIT> and <CIT>. Another suitable topsheet may be formed from a three-dimensional substrate as detailed in <CIT>. The topsheet may have one or more layers, as described in <CIT>; <CIT>; and <CIT>. The topsheet may be apertured, as described in <CIT>.

As contemplated herein, component nonwoven web material from which topsheet <NUM> be cut may be a nonwoven web material that includes or consists predominately (by weight) or entirely of cellulosic plant fibers such as fibers of cotton, flax, hemp, jute or mixtures thereof, that are either naturally hydrophilic or suitably processed so as be rendered hydrophilic (or have increased hydrophilicity) and processed to be suitably soft. Plant-based fibers may be preferred to appeal to consumer preferences for natural products. In other examples, semisynthetic fibers derived from cellulosic material, such as rayon (including viscose, lyocell, MODAL (a product of Lenzing AG, Lenzing, Austria) and cuprammonium rayon may be used. In some examples a topsheet cut from a carded nonwoven including or consisting predominately (by weight) or entirely of cotton fibers may be preferred. In some examples, the nonwoven web material may be formed via a carding process. In some other examples the nonwoven web material may be formed in a co-forming process in which plant-based fibers of finite lengths are physically blended or mixed with streams of filaments of indefinite lengths, spun from polymeric resin, and laid down on a forming belt to form a web as described in, for example, <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT> and <CIT>.

For purposes of limiting bulk and caliper (thickness) of the pad for the purpose of providing a thin pad facilitating compact folding and packaging as described below, it may be desired that the topsheet be disposed in direct face-to-face relationship with the absorbent layer, with no intervening layer disposed therebetween. Alternatively, an intervening layer, if included (such as a secondary topsheet or acquisition layer), may be formed of a nonwoven web material having a basis weight no greater than <NUM> gsm, more preferably no greater than <NUM> gsm, even more preferably no greater than <NUM> gsm, and still more preferably no greater than <NUM> gsm.

In some examples the absorbent layer <NUM> may be formed of or include a layer of absorbent open-celled foam material. In some examples, the foam material may include at least first and second sublayers 40a, 40b (<FIG>) of absorbent open-celled foam material, the sublayers being in direct face-to-face contact with each other. In such examples, the wearer-facing sublayer may be a relatively larger-celled foam material, and the outward-facing sublayer may be a relatively smaller-celled foam material, for purposes explained in more detail below. In some examples it may be desired that the layer of absorbent open-celled foam material provide the majority, substantially most or all of the absorption capacity of the pad. This feature minimizes the number of components present to impart bulk to the pad when folded and packaged, and when in use.

The open-celled foam material may be a foam material that is manufactured via polymerization of the continuous oil phase of a water-in-oil high internal phase emulsion ("HIPE").

A water-in-oil HIPE has two phases. One phase is a continuous oil phase comprising monomers to be polymerized, and an emulsifier to help stabilize the HIPE. The oil phase may also include one or more photoinitiators. The monomer component may be present in an amount of from about <NUM>% to about <NUM>%, and in certain examples from about <NUM>% to about <NUM>% by weight of the oil phase. The emulsifier component, which is soluble in the oil phase and suitable for forming a stable water-in-oil emulsion may be present in the oil phase in an amount of from about <NUM>% to about <NUM>% by weight of the oil phase. The emulsion may be formed at an emulsification temperature of from about <NUM>° C to about <NUM>° C and in certain examples from about <NUM>° C to about <NUM>° C.

In general, the monomers will include from about <NUM>% to about <NUM>% by weight of the oil phase at least one substantially water-insoluble monofunctional alkyl acrylate or alkyl methacrylate. For example, monomers of this type may include C4-C18 alkyl acrylates and C2-C18 methacrylates, such as ethylhexyl acrylate, butyl acrylate, hexyl acrylate, octyl acrylate, nonyl acrylate, decyl acrylate, isodecyl acrylate, tetradecyl acrylate, benzyl acrylate, nonyl phenyl acrylate, hexyl methacrylate, <NUM>-ethylhexyl methacrylate, octyl methacrylate, nonyl methacrylate, decyl methacrylate, isodecyl methacrylate, dodecyl methacrylate, tetradecyl methacrylate, and octadecyl methacrylate.

The oil phase may also comprise from about <NUM>% to about <NUM>%, and in certain examples from about <NUM>% to about <NUM>%, by weight of the oil phase, a substantially water-insoluble, polyfunctional crosslinking alkyl acrylate or methacrylate. This crosslinking comonomer, or crosslinker, is added to confer strength and resilience to the resulting HIPE foam. Examples of crosslinking monomers of this type comprise monomers containing two or more activated acrylate, methacrylate groups, or combinations thereof. Nonlimiting examples of this group include <NUM>,<NUM>-hexanedioldiacrylate, <NUM>,<NUM>-butanedioldimethacrylate, trimethylolpropane triacrylate, trimethylolpropane trimethacrylate, <NUM>,<NUM><NUM>-dodecyldimethacrylate, <NUM>,<NUM>-tetradecanedioldimethacrylate, ethylene glycol dimethacrylate, neopentyl glycol diacrylate (<NUM>,<NUM>-dimethylpropanediol diacrylate), hexanediol acrylate methacrylate, glucose pentaacrylate, sorbitan pentaacrylate, and the like. Other examples of crosslinkers contain a mixture of acrylate and methacrylate moieties, such as ethylene glycol acrylate-methacrylate and neopentyl glycol acrylate-methacrylate. The ratio of methacrylate:acrylate group in the mixed crosslinker may be varied from <NUM>:<NUM> to any other ratio as needed.

Any third substantially water-insoluble comonomer may be added to the oil phase in weight percentages of from about <NUM>% to about <NUM>% by weight of the oil phase, in certain examples from about <NUM>% to about <NUM>%, to modify properties of the HIPE foams. In certain cases, "toughening" monomers may be desired which impart toughness to the resulting HIPE foam. These include monomers such as styrene, vinyl chloride, vinylidene chloride, isoprene, and chloroprene. Without being bound by theory, it is believed that such monomers aid in stabilizing the HIPE during polymerization (also known as "curing") to provide a more homogeneous and better formed HIPE foam which results in better toughness, tensile strength, abrasion resistance, and the like. Monomers may also be added to confer flame retardancy as disclosed in <CIT>. Monomers may be added to confer color, for example vinyl ferrocene, fluorescent properties, radiation resistance, opacity to radiation, for example lead tetraacrylate, to disperse charge, to reflect incident infrared light, to absorb radio waves, to form a wettable surface on the HIPE foam struts, or for any other desired property in a HIPE foam. In some cases, these additional monomers may slow the overall process of conversion of HIPE to HIPE foam, the tradeoff being necessary if the desired property is to be conferred. Thus, such monomers can be used to slow down the polymerization rate of a HIPE. Examples of monomers of this type comprise styrene and vinyl chloride.

The oil phase may further contain an emulsifier used for stabilizing the HIPE. Emulsifiers used in a HIPE can include: (a) sorbitan monoesters of branched C16-C24 fatty acids; linear unsaturated C16-C22 fatty acids; and linear saturated C12-C14 fatty acids, such as sorbitan monooleate, sorbitan monomyristate, and sorbitan monoesters, sorbitan monolaurate diglycerol monooleate (DGMO), polyglycerol monoisostearate (PGMIS), and polyglycerol monomyristate (PGMM); (b) polyglycerol monoesters of -branched C16-C24 fatty acids, linear unsaturated C16-C22 fatty acids, or linear saturated C12-C14 fatty acids, such as diglycerol monooleate (for example diglycerol monoesters of C18:<NUM> fatty acids), diglycerol monomyristate, diglycerol monoisostearate, and diglycerol monoesters; (c) diglycerol monoaliphatic ethers of - branched C16-C24 alcohols, linear unsaturated C16-C22 alcohols, and linear saturated C12-C14 alcohols, and mixtures of these emulsifiers. See <CIT> and <CIT>. Another emulsifier that may be used is polyglycerol succinate (PGS), which is formed from an alkyl succinate, glycerol, and triglycerol.

Such emulsifiers, and combinations thereof, may be added to the oil phase so that they comprise between about <NUM>% and about <NUM>%, in certain examples from about <NUM>% to about <NUM>%, and in certain other examples from about <NUM>% to about <NUM>% by weight of the oil phase In certain examples, coemulsifiers may also be used to provide additional control of cell size, cell size distribution, and emulsion stability, particularly at higher temperatures, for example greater than about <NUM>° C. Examples of coemulsifiers include phosphatidyl cholines and phosphatidyl choline-containing compositions, aliphatic betaines, long chain C12-C22 dialiphatic quaternary ammonium salts, short chain C1-C4 dialiphatic quaternary ammonium salts, long chain C12-C22 dialkoyl(alkenoyl)-<NUM>-hydroxyethyl, short chain C1-C4 dialiphatic quaternary ammonium salts, long chain C12-C22 dialiphatic imidazolinium quaternary ammonium salts, short chain C1-C4 dialiphatic imidazolinium quaternary ammonium salts, long chain C12-C22 monoaliphatic benzyl quaternary ammonium salts, long chain C12-C22 dialkoyl(alkenoyl)-<NUM>-aminoethyl, short chain C1-C4 monoaliphatic benzyl quaternary ammonium salts, short chain C1-C4 monohydroxyaliphatic quaternary ammonium salts. In certain examples, ditallow dimethyl ammonium methyl sulfate (DTDMAMS) may be used as a coemulsifier.

Photoinitiators may comprise between about <NUM>% and about <NUM>%, and in certain examples between about <NUM>% and about <NUM>% by weight of the oil phase. Lower amounts of photoinitiator allow light to better penetrate the HIPE foam, which can provide for polymerization deeper into the HIPE foam. However, if polymerization is done in an oxygen-containing environment, there should be enough photoinitiator to initiate the polymerization and overcome oxygen inhibition. Photoinitiators can respond rapidly and efficiently to a light source with the production of radicals, cations, and other species that are capable of initiating a polymerization reaction. The photoinitiators used in forming foams within contemplation of the present disclosure may absorb UV light at wavelengths of about <NUM> nanometers (nm) to about <NUM>, in certain examples about <NUM> to about <NUM>. If the photoinitiator is in the oil phase, suitable types of oil-soluble photoinitiators include benzyl ketals, α-hydroxyalkyl phenones, α-amino alkyl phenones, and acylphospine oxides. Examples of photoinitiators include <NUM>,<NUM>,<NUM>-[trimethylbenzoyldiphosphine]oxide in combination with <NUM>-hydroxy-<NUM>-methyl-<NUM>-phenylpropan-<NUM>-one (<NUM>:<NUM> blend of the two is sold by Ciba Specialty Chemicals, Ludwigshafen, Germany as DAROCUR <NUM>); benzyl dimethyl ketal (sold by Ciba Geigy as IRGACURE <NUM>); α-,α-dimethoxy-α-hydroxy acetophenone (sold by Ciba Specialty Chemicals as DAROCUR <NUM>); <NUM>-methyl-<NUM>-[<NUM>-(methyl thio)phenyl]-<NUM>-morpholino-propan-<NUM>-one (sold by Ciba Specialty Chemicals as IRGACURE <NUM>); <NUM>-hydroxycyclohexyl-phenyl ketone (sold by Ciba Specialty Chemicals as IRGACURE <NUM>); bis(<NUM>,<NUM>,<NUM>-trimethylbenzoyl)-phenylphosphineoxide (sold by Ciba Specialty Chemicals as IRGACURE <NUM>); diethoxyacetophenone, and <NUM>-(<NUM>-hydroxyethoxy)phenyl-(<NUM>-hydroxy-<NUM>-methylpropyl)ketone (sold by Ciba Specialty Chemicals as IRGACURE <NUM>); and Oligo [<NUM>-hydroxy-<NUM>-methyl-<NUM>-[<NUM>-(<NUM>-methylvinyl)phenyl]propanone] (sold by Lamberti spa, Gallarate, Italy as ESACURE KIP EM).

The dispersed aqueous phase of a HIPE comprises water, and may also comprise one or more components, such as initiator, photoinitiator, or electrolyte, wherein in certain examples, the one or more components are at least partially water soluble.

One component of the aqueous phase may be a water-soluble electrolyte. The water phase may contain from about <NUM>% to about <NUM>%, in certain examples from about <NUM>% to about <NUM>%, by weight of the aqueous phase of a water-soluble electrolyte. The electrolyte minimizes the tendency of monomers, comonomers, and crosslinkers that are primarily oil soluble to also dissolve in the aqueous phase. Examples of electrolytes include chlorides or sulfates of alkaline earth metals such as calcium or magnesium and chlorides or sulfates of alkali earth metals such as sodium. Such electrolyte can include a buffering agent for the control of pH during the polymerization, including such inorganic counterions as phosphate, borate, and carbonate, and mixtures thereof. Water soluble monomers may also be used in the aqueous phase, examples being acrylic acid and vinyl acetate.

Another component that may be present in the aqueous phase is a water-soluble free-radical initiator. The initiator can be present at up to about <NUM> mole percent based on the total moles of polymerizable monomers present in the oil phase. In certain examples, the initiator is present in an amount of from about <NUM> to about <NUM> mole percent based on the total moles of polymerizable monomers in the oil phase. Suitable initiators include ammonium persulfate, sodium persulfate, potassium persulfate, <NUM>,<NUM>'-azobis(N,N'-dimethyleneisobutyramidine)dihydrochloride, azo initiators, redox couples like persulfate-bisulfate, persulfate-ascorbic acid, and other suitable redox initiators. In certain examples, to reduce the potential for premature polymerization which may clog the emulsification system, addition of the initiator to the monomer phase may be just after or near the end of emulsification.

Photoinitiators present in the aqueous phase may be at least partially water soluble and may comprise between about <NUM>% and about <NUM>%, and in certain examples between about <NUM>% and about <NUM>% by weight of the oil phase. Lower amounts of photoinitiator allow light to better penetrate the HIPE foam, which can provide for polymerization deeper into the HIPE foam. However, if polymerization is done in an oxygen-containing environment, there should be enough photoinitiator to initiate the polymerization and overcome oxygen inhibition. Photoinitiators can respond rapidly and efficiently to a light source with the production of radicals, cations, and other species that are capable of initiating a polymerization reaction. The photoinitiators used to form foams within contemplation of the present disclosure may absorb UV light at wavelengths of from about <NUM> nanometers (nm) to about <NUM>, in certain examples from about <NUM> to about <NUM>, and in certain examples from about <NUM> to about <NUM>. If the photoinitiator is in the aqueous phase, suitable types of water-soluble photoinitiators include benzophenones, benzils, and thioxanthones. Examples of photoinitiators include <NUM>,<NUM>'-Azobis[<NUM>-(<NUM>-imidazolin-<NUM>-yl)propane]dihydrochloride; <NUM>,<NUM>'-Azobis[<NUM>-(<NUM>-imidazolin-<NUM>-yl)propane]disulfate dehydrate; <NUM>,<NUM>'-Azobis(<NUM>-imino-<NUM>-pyrrolidino-<NUM>-ethylpropane)dihydrochloride; <NUM>,<NUM>'-Azobis[<NUM>-methyl-N-(<NUM>-hydroxyethyl)propionamide]; <NUM>,<NUM>'-Azobis(<NUM>-methylpropionamidine)dihydrochloride; <NUM>,<NUM>'-dicarboxymethoxydibenzalacetone, <NUM>,<NUM>'-dicarboxymethoxydibenzalacetone, <NUM>,<NUM>'-dicarboxymethoxydibenzalcyclohexanone, <NUM>-dimethylamino-<NUM>'-carboxymethoxydibenzalacetone; and <NUM>,<NUM>'-disulphoxymethoxydibenzalacetone. Other suitable photoinitiators that can be used are listed in <CIT>.

In addition to the previously described components other components may be included in either the aqueous or oil phase of a HIPE. Examples include antioxidants, for example hindered phenolics, hindered amine light stabilizers; plasticizers, for example dioctyl phthalate, dinonyl sebacate; flame retardants, for example halogenated hydrocarbons, phosphates, borates, inorganic salts such as antimony trioxide or ammonium phosphate or magnesium hydroxide; dyes and pigments; fluorescers; filler particles, for example starch, titanium dioxide, carbon black, or calcium carbonate; fibers; chain transfer agents; odor absorbers, for example activated carbon particulates; dissolved polymers; dissolved oligomers; and the like.

HIPE foam is produced from the polymerization of the monomers comprising the continuous oil phase of a HIPE. In certain examples, a HIPE foam layer may have one or more sublayers, and may be either homogeneous or heterogeneous polymeric open-celled foams. Homogeneity and heterogeneity relate to distinct layers within the same HIPE foam, which are similar in the case of homogeneous HIPE foams or which differ in the case of heterogeneous HIPE foams. A heterogeneous HIPE foam may contain at least two distinct sublayers that differ with regard to their chemical composition, physical properties, or both; for example layers may differ with regard to one or more of foam density, polymer composition, specific surface area, or pore size (also referred to as cell size). For example, for a HIPE foam, if the difference relates to pore size, the average pore size in the respective sublayers may differ by at least about <NUM>%, in certain examples by at least about <NUM>%, and in still other examples by at least about <NUM>%. In another example, if the differences in the sublayers of a HIPE foam layer relate to density, the densities of the layers may differ by at least about <NUM>%, in certain examples by at least about <NUM>%, and in still other examples by at least about <NUM>%. For instance, if one layer of a HIPE foam has a density of <NUM>/cc, another layer may have a density of at least about <NUM>/cc or less than about <NUM>/cc, in certain examples at least about <NUM>/cc or less than about <NUM>/cc, and in still other examples at least about <NUM>/cc or less than about <NUM>/cc. If the differences between the layers are related to the chemical composition of the HIPE or HIPE foam, the differences may reflect a relative amount difference in at least one monomer component, for example by at least about <NUM>%, in certain examples by at least about <NUM>%, and in still further examples by at least about <NUM>%. For instance, if one sublayer of a HIPE or HIPE foam is composed of about <NUM>% styrene in its formulation, another sublayer of the HIPE or HIPE foam may be composed of at least about <NUM>%, and in certain examples of at least about <NUM>%.

A HIPE foam layer structured to have distinct sublayers formed from differing HIPEs may provide a HIPE foam layer with a range of desired performance characteristics. For example, a HIPE foam absorbent layer comprising first and second foam sublayers, wherein a first wearer-facing sublayer has a relatively larger pore or cell size, than the second sublayer, may more quickly absorb incoming fluids than the second sublayer. The first foam sublayer may be overlaid and be adjacent/continuous with or otherwise in contact with the second foam sublayer having relatively smaller pore sizes, and the second sublayer which exert greater capillary pressure and draw the acquired fluid from the first foam sublayer, restoring the first foam sublayer's ability to acquire more fluid. HIPE foam pore sizes may range from <NUM> to <NUM> and in certain examples may be less than <NUM>. HIPE foam layers of the present disclosure having two major parallel surfaces may be from about <NUM> to about <NUM> thick, and in certain examples from about <NUM> to about <NUM>. The desired thickness of a HIPE foam layer will depend on the materials used to form the HIPE foam layer, the speed at which a HIPE is deposited on a belt, and the intended use of the resulting HIPE foam layer.

The HIPE foam layers of the present disclosure may be manufactured to be relatively open-celled. This refers to a structure in which the individual cells or pores of the HIPE foam layer are in substantially unobstructed communication with adjoining cells. The cells in such substantially open-celled HIPE foam structures have intercellular openings or windows that are large enough to permit ready fluid transfer from one cell to its adjacent cells within the HIPE foam structure. For purpose of the present disclosure, a HIPE foam is considered "open-celled" if at least about <NUM>% of the cells in the HIPE foam that are at least <NUM> in size are in fluid communication with at least one adjoining cell.

In addition to being open-celled, in certain examples HIPE foams are sufficiently hydrophilic to permit the HIPE foam to absorb aqueous fluids, for example the internal surfaces of a HIPE foam may be rendered hydrophilic by residual hydrophilizing surfactants or salts left in the HIPE foam following polymerization, by selected post-polymerization HIPE foam treatment procedures (as described hereafter), or combinations of both.

In certain examples, for example when used to form an absorbent layer, a HIPE foam layer may be flexible and exhibit an appropriate glass transition temperature (Tg). The Tg represents the midpoint of the transition between the glassy and rubbery states of the polymer. In general, HIPE foams that have a higher Tg than the temperature of use can be suitably strong but will also be relatively rigid and potentially prone to fracture. In certain examples, regions of the HIPE foams of the current disclosure which exhibit either a relatively high Tg or excessive brittleness will be discontinuous. Since these discontinuous regions will also generally exhibit high strength, they can be prepared at lower densities without compromising the overall strength of the HIPE foam.

HIPE foams intended for applications requiring flexibility should contain at least one continuous region having a Tg as low as possible, so long as the overall HIPE foam has acceptable strength at in-use temperatures. In certain examples, the Tg of this region will be less than about <NUM>° C for foams used at about ambient temperature conditions, in certain other examples less than about <NUM>° C. For HIPE foams used in applications wherein the use temperature is higher or lower than ambient, the Tg of the continuous region may be no more than <NUM>° C greater than the use temperature, in certain examples the same as use temperature, and in further examples about <NUM>° C less than use temperature wherein flexibility is desired. Accordingly, monomers are selected as much as possible that provide corresponding polymers having lower Tg's.

HIPE foams useful for forming absorbent layers and/or sublayers within contemplation of the present disclosure, and methods for their manufacture, also include but are not necessarily limited to those foams and methods described in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>;<CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>.

As reflected in <FIG>, the absorbent layer formed of HIPE foam may include one or more patterns of perforations <NUM>, including at least a first pattern disposed within an expected discharge region overlying the intersection of longitudinal and lateral axes <NUM>, <NUM> of the pad. Perforations <NUM> may be punched, cut or otherwise formed through the entire z-direction depth of the HIPE foam absorbent layer, or only through a wearer-facing layer or partially into the wearer-facing portion thereof. When a HIPE foam absorbent layer is disposed directly beneath a topsheet as described herein, with no intervening acquisition layer formed of another material, perforations <NUM> may serve as a group of reservoirs to receive, temporarily hold, and aid in distributing rapid discharges of relatively small quantities of menstrual fluid, until the HIPE foam has sufficient time to distribute and absorb the fluid via capillary action. Additionally, such perforations help decrease bending stiffness of the absorbent layer, which may help increase both comfort and foldability. A more detailed description of configurations of such perforations in combination with examples of suitable absorbent layers may be found in <CIT>.

The backsheet <NUM> may be positioned adjacent an outward-facing surface of the absorbent layer <NUM> and may be joined thereto by any suitable attachment methods. For example, the backsheet <NUM> may be secured to the absorbent layer <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 method may include heat bonds, pressure bonds, ultrasonic bonds, dynamic mechanical bonds, or any other suitable attachment mechanisms or combinations thereof. In other examples, it is contemplated that the absorbent layer <NUM> is not joined directly to the backsheet <NUM>.

The backsheet <NUM> may be impervious, or substantially impervious, to liquids (e.g., urine, menstrual fluid) 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 substantially inhibit, fluids absorbed and contained within the absorbent layer <NUM> from escaping and reaching articles of the wearer's clothing which may contact the pad <NUM> such as underpants and outer clothing. However, in some instances, the backsheet <NUM> may be made and/or adapted to permit vapor to escape from the absorbent layer <NUM> (i.e., the backsheet may be made to be breathable), while in other instances the backsheet <NUM> may be made so as not to permit vapors to escape (i.e., it may be made to be 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>; <CIT>; <CIT> and <CIT>.

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

Referring to <FIG>, <FIG> and <FIG>, a particular folding arrangement for the pad, to be placed inside an individual package, may be employed. This folding arrangement can be facilitated in some circumstances by construction of a thin pad utilizing an open-cell foam HIPE material for the absorbent layer, as described above. Open-celled HIPE foam provides advantages that include a thin and highly foldable but still suitably absorbent layer. It has been discovered that an absorbent layer of open-celled HIPE foam has greater resiliency and thereby enables a pad to take on less "set" from folding, than a pad having an absorbent layer of other absorbent materials that may cellulosic fiber and absorbent gelling material (or superabsorbent polymer material). Consequently, an absorbent layer formed of HIPE foam will more easily and completely return toward its open, flattened configuration following unpackaging and unfolding. It has been learned that this feature is desired by users because it reduces effort needed to manipulate the pad for positioning within the underpants. Further, the resiliency of the absorbent layer and the material forming it helps ensure that fluid transfer within the absorbent layer and along its length will be less likely to be interrupted or obstructed by permanently compressed/deformed regions created by folding, along the fold lines.

It has been learned, further, that this folding arrangement may be further facilitated and improved by the two-layer HIPE foam structure described above (and pictured in <FIG>, with a relatively larger-celled wearer-facing layer 40a and a relatively smaller-celled outward-facing layer 40b). Without intending to be bound by theory, it is believed that a relatively smaller-celled HIPE foam in an outward-facing layer 40b, having a greater number and density of cell walls and struts, has greater tensile strength needed to withstand the stress imposed on the outsides of the lateral folds (as described below) without substantial damage, while the relatively larger-celled wearer-facing layer 40a, having a lesser number and density of cell walls and struts, has greater compressibility and is more amenable to being compressed on the insides of the lateral folds. In other examples, an absorbent structure formed of or including a heterogeneous mass or layer assembly that includes a combination of relatively open-celled foam, such as but not limited to HIPE foam, in one or a plurality of discrete sections or pieces, layered and/or intermingled with fibers of a nonwoven web such that these components are present in a singularized layer, may provide a highly flexible, thin, foldable absorbent structure that substantially retains its fluid distribution and absorbency properties despite being folded as described herein. Non-limiting examples of such layer assemblies and/or heterogeneous masses are described in, for example, <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>; and U.

As depicted in the figures, pad <NUM> may first be folded about side longitudinal fold lines <NUM>, about which wings <NUM> are folded laterally over the wearer-facing surface of the pad. Following such folding, one or more suitably-sized section(s) of a thin release film or paper (not shown) may be laid over and applied to the portions of the wings having backsheet adhesive <NUM> deposited thereon, to cover the adhesive and protect it from unwanted sticking, until the time the user wishes to apply the pad to her underpants. To avoid unnecessarily adding caliper to the pad in the completely folded configuration, it may be desired to avoid folding the pad along any longitudinal fold lines that traverse the absorbent layer or polymeric foam material included in the absorbent layer. As noted above, the central outward-facing surfaces of the pad having backsheet adhesive <NUM> deposited thereon may also be covered with one or more sections of release film or paper (not shown).

After folding of the wings <NUM> about side longitudinal fold lines <NUM>, the pad may be further folded into at least four sections including front section <NUM>, front-mid section <NUM>, rear-mid section <NUM> and rear section <NUM>, along at least a front lateral fold line <NUM>, middle lateral fold line <NUM> and rear lateral fold line <NUM>. Middle lateral fold line <NUM> may, but does not necessarily have to, coincide with pad lateral axis <NUM>. Sections <NUM>, <NUM>, <NUM> and <NUM> may be approximately equal in length, or the lengths of each (i.e., the positions of the lateral folding lines) may be adjusted to facilitate folding of one section length inside another section length.

Along lateral folding lines <NUM>, <NUM> and <NUM>, the pad may be folded into at least four sections <NUM>, <NUM>, <NUM> and <NUM> in a number of ways. However, for dual, but unrelated, purposes of (<NUM>) providing a folded pad configuration 10a with a singularized fold nose <NUM>, and (<NUM>) minimizing folding damage to an absorbent layer formed of two layers of open-celled HIPE foam material as described above, one of two folding configurations may be applied.

The first is a "roll" fold configuration depicted in <FIG>. In a roll fold configuration, rear section <NUM> is folded along about rear lateral fold line <NUM> over rear-mid section <NUM>; then both sections <NUM> and <NUM> together are folded about middle lateral fold line <NUM> over front-mid section <NUM>; and lastly, the three section <NUM>, <NUM> and <NUM> together are folded about front lateral fold line <NUM> over front section <NUM>. The foregoing procedure results in a front-section-out roll fold configuration, in which front section <NUM> and forward end <NUM> are disposed on the outside of the folded pad configuration 10a as shown in <FIG>. It will be appreciated that an alternative roll fold configuration as described above may be formed by first folding the front section <NUM> over about front lateral fold line <NUM>, and preceding to fold rearward, resulting in a rear-section-out roll fold configuration, in which rear section <NUM> and rearward end <NUM> lie on the outside of the folded configuration. A front-section-out roll fold configuration as shown in <FIG> may be desired, however, for purposes of user convenience, because it provides for front-to-rear unfolding that may be more intuitive for the user. It will be appreciated that a front-section-out roll fold configuration, or a rear-section-out roll fold configuration (if desired), may be created via steps that differ from those described above.

The second configuration is a "book jacket" fold configuration, named herein because it resembles the manner in which a book jacket (or book dust jacket) is folded, and is depicted in <FIG>. In a book jacket fold configuration, front section <NUM> is folded about front lateral fold line <NUM> over front-mid section <NUM>; and rear second <NUM> is folded about rear lateral fold line <NUM> over rear-mid section <NUM> (these two folds can occur simultaneously or one after another in either order). Finally, the two remaining portions comprising front section <NUM> folded over front-mid section <NUM> as one portion, and rear section <NUM> folded over rear-mid section <NUM>, are folded about middle lateral fold line <NUM> to bring them together to create the book jacket fold configuration depicted in <FIG>.

It will be appreciated that in both the roll and book jacket fold configurations depicted and described, in all folds about lateral fold lines <NUM>, <NUM> and <NUM>, the fold is formed with the wearer-facing (i.e., topsheet) surfaces facing inward in the fold. This serves three purposes. First, it is believed that it provides for more intuitive, and therefore more convenient, unfolding for the user. Second, it cooperates with an absorbent layer formed of two sublayers of open-celled HIPE foam, as described above, to help minimize permanent deformation, or damage, to the absorbent layer resulting from folding.

Third, it can be seen in <FIG> that both the roll fold configuration and the book jacket fold configuration result in an isolated and singularized main fold nose <NUM>, wherein an outside folded edge along one of the lateral fold lines is alone, with no proximate folded or end edges present - in contrast to the secondary fold nose <NUM> proximate to end edge <NUM> shown at the bottom of <FIG> and proximate secondary fold noses <NUM>, <NUM> shown at the bottom of <FIG>). A singularized main fold nose <NUM> may be desired for purposes of user convenience and user perceptions of greater imperviousness to contamination of the product, as will be described below.

Referring to <FIG>, <FIG>, for purposes of providing a package for an individual folded feminine hygiene pad that can be easily and quietly opened by a user, it may be desired to provide a package having some or all of the features depicted and described herein. Package <NUM> has an envelope configuration as depicted. It may be formed from a single sheet of polymeric film material, or laminate of a nonwoven web material and polymeric film material. The single sheet of material may be cut to appropriate length, size and shape configured to provide front panel <NUM>, rear panel <NUM> and closure flap <NUM>, wherein front panel <NUM> is cut to provide an extended access front opening edge <NUM> visible in an opened configuration shown in <FIG>, and a closure flap <NUM> that may in some examples be configured to overlie and cover front opening edge <NUM> when in the closed configuration as shown in <FIG> (flap <NUM> folded about closure flap fold line <NUM>). The cut package material may be folded as shown and then ultrasonically, thermally, compressively and/or adhesively bonded alongside edges thereof to form side seams <NUM> and thereby form the envelope structure. In order to minimize the size of the package, it may be desired to minimize the margin of film material along the side seams that is present in the seams, and utilize a thermal bonding-fusion mechanism (e.g., by application of heat directly, or via ultrasonic means) that results in side seams formed of welded/fused film material that are no more than <NUM> in width, more preferably no more than <NUM> in width, and even more preferably no more than <NUM> in width.

Where the package includes a polymeric film material, it may be desired that the film material have properties that make it relatively quiet when handled or manipulated, for purposes of providing a discreet package. In some examples, the film material may comprise polyethylene. In some examples the polymer resin from which the film is formed may include a particle filler or additive, such as particles of calcium carbonate. Without intending to be bound by theory, it is believed that such particle fillers may beneficially reduce noise generation/transmission characteristics of the polymer film. Nonlimiting examples of suitable polymer film and particle filler compositions are disclosed in <CIT> and <CIT>.

Many currently marketed feminine hygiene pads are individually packaged in packages that require the consumer to destructively tear the package along seams or through the package material itself, to access the pad within. Such destructive opening creates the potential to material itself, to access the pad within. Such destructive opening creates the potential to generate, or actually generates, unwanted noise during package opening. In order to further minimize noise created by opening of the package, and to preserve the package structure so it can be used to receive and hold a used pad for later disposal, it may be desired that the package be configured so that it can be opened without substantial destruction thereto. In some examples, the packaging may be configured such that accessing the pad within requires separating the package material along a total/combined distance of no more than <NUM> percent of the total length of all seams present, more preferably no more than <NUM> percent of the total length of all seams present, and even more preferably no more than <NUM> percent of the total length of all seams present.

In some examples, an openable closure element may be provided, in combination with any of the other package features described herein. In some examples a closure element may include a releasable flap closure adhesive 60a on the underside of the flap <NUM>, or panel closure adhesive 60c on the outside of the package front panel <NUM>, and in some examples may include an adhesive closure tape or sticker 60b that overlies the edge of closure flap <NUM> and adheres to the front panel <NUM> of package <NUM>. In some examples the closure element may be a deposit of releasable closure adhesive 60a (e.g., in a position as depicted in <FIG>) alone, applied to the underside of flap <NUM> in a suitable position and shape to adhere the flap to front panel <NUM> without contacting a pad contained in the package. Such adhesive may be applied in a position on the flap so as to be present along most or substantially the entire opening edge <NUM> when the flap <NUM> is closed (i.e., extending substantially along the flap edge and/or opening edge <NUM> from one side seam <NUM> to the other), to make a more complete closure that reduces chances of contamination of a new pad within the package. In some examples a deposit of releasable panel closure adhesive 60c may be disposed on the front panel <NUM>, which may be desired to minimize likelihood of inadvertent contact with the pad. In some examples the releasable adhesive may also be reusable/refastenable, which may make the package <NUM> more useful for storing a used pad for disposal.

In some examples such as depicted in <FIG>, an envelope package may be formed about a pad in a flow-wrap process in which a seam <NUM> is created in back panel <NUM>. As depicted in <FIG>, seam <NUM> is a fin seam; however, seam <NUM> may also be in the form of an overlap seam that lies flush along the rear panel <NUM>. Either a fin seam or an overlap seam may be formed and held together via thermal bonding/fusion of the separate portions of film joined therealong, by a deposit of a suitable adhesive between the separate portions of film, or a combination thereof. In some examples it may be desired that attachment between the joined sections forming back panel <NUM>, at seam <NUM>, whether effected by adhesive or by welding/fusion, be intermittent or discontinuous and may have spaced intervals of attachment, rather than being continuous, along seam <NUM>. This may be desired to allow venting of air from the finished package upon compression of the package, such as may occur in processes downstream of package formation, reducing chances that the package will burst open along seams or along the flap closure.

Still referring to <FIG>, rather than be separate of film forming front panel <NUM>, flap <NUM> is contiguous and integral with film forming front panel <NUM>, and may be defined along edge <NUM> by a path of perforations, laser scoring, mechanical scoring or cutting or other suitable mechanism for imparting a path of separation along which front panel <NUM> and flap <NUM> will easily tear away or separate from each other. A larger flap sticker 60d with flap sticker adhesive 60e disposed to hold it to the front panel <NUM> and flap <NUM> overlies the path of separation and thereby prevent opening of the package until desired by the user. When the user wishes to open the package, she may lift and peal the flap sticker 60d upwardly, and the adhered flap sticker 60d will pull the flap <NUM> along therewith, causing the front panel <NUM> and flap <NUM> to separate along the path of separation to create access opening edge <NUM>. In some examples the film forming front panel <NUM> may be cut (such as by die-cutting) substantially entirely through its thickness along the path of separation during the manufacturing/packaging process, following application of flap sticker 60d to the package film, such that the flap sticker 60d and flap sticker adhesive 60e thereunder are the only structure that effectively holds the flap in a closed position after packaging is completed. This may provide for a particularly quiet flap opening experience for the user, when a suitable flap sticker adhesive composition is included, because the user will not need to tear the film of the front panel (which has a potential to generate noise) to open the package. In some examples it may be desired that the flap sticker be of a size and shape suitable to cover the entirety of the path of separation. Such a feature may serve to enhance the ability of the package to protect a new pad from contamination prior to use; to create favorable consumer perceptions resulting from such effect; and to make the package a more effective container/disposal aid for receiving, isolating and carrying a used pad until the time the user can dispose of it.

As may be appreciated from <FIG>, in some examples a flap sticker 60d may include a lift tab <NUM>. Lift tab <NUM> may simply be an extension of the distal end of flap sticker 60d. Lift tab <NUM> or a distal portion thereof may be provided with a reduced amount, or entirely without, any adhesive 60e thereon. In such configuration, lift tab <NUM> may easily be lifted away from front panel <NUM> and grasped by the consumer, facilitating the consumer's lifting and peeling upward of flap sticker 60d and/or flap <NUM> to open the package.

It will be appreciated that a package configuration such as any of those depicted in <FIG>, <FIG>, <FIG>, <FIG> and described herein, may be configured so as to be openable with substantially limited or even no destruction thereto, and to be recloseable, so as to make it suitable to serve as a disposal aid - into which the user may insert a used, folded pad, and reclose the package around it, to isolate the used pad until a convenient time for disposal thereof. Where an openable flap <NUM> is provided, it may be configured to be openable without substantial destruction of the flap itself, and without substantial destruction or separations of other portions of the package (e.g. side seams <NUM>), such that the flap is effectively recloseable to cover the access opening. Additionally, a reclosure refastenability feature may be provided, such as, for example a releaseable/refastenable flap closure adhesive 60a beneath the flap or a releasable/refastenable adhesive 60e beneath a flap sticker 60b or 60d, such that the flap <NUM> and access opening may be fastenably reclosed after opening.

As may be appreciated from the figures, in some examples it may be desired that the opening edge <NUM> follow a curving path, which will avoid localization of stresses therealong and thereby avoid unintended tearing of the package film. In some examples it may be desired that the curving path be configured such that a greatest portion of the contained folded pad is exposed and made accessible to the user at a location between the side seams <NUM>, for purposes of user convenience.

It may be desired that the package <NUM> be sized relative the folded pad 10a, so as to be as small as possible (for convenient and discreet carry) without being so snug as to create friction between the folded pad 10a and the insides of the package sufficient to frustrate easy and quiet withdrawal of the pad from the package. Similarly, and also for purposes of nondestructive and easy withdrawal of the pad from the package, it may be desired that the folded pad 10a and the package <NUM> be configured such that there are few or no substantial deposits of adhesive, preferably no deposits of adhesive, disposed between the outside surfaces of the folded pad 10a and the inside surfaces of the package <NUM> and/or the closure flap <NUM>.

Through prototyping, it has been discovered that a normal-capacity daytime use feminine hygiene pad of the same design and materials as current ALWAYS INFINITY pads (a product of The Procter & Gamble Company, Cincinnati, Ohio) and having an absorbent layer formed of an open-celled HIPE foam, can be folded and packaged as described herein to have an uncompressed package caliper when laid flat on a horizontal surface of <NUM> or less, more preferably <NUM> or less, even more preferably <NUM> or less, or from <NUM> to <NUM>, more preferably from from <NUM> to <NUM>, and even more preferably from <NUM> to <NUM> - following removal from a larger package containing a plurality of individually packaged pads, and a <NUM>-hour rest period. This package caliper contributes to providing a relatively small packaged pad believed to be preferred by many consumers for its discreet pocketability and ease of discreet one-hand carry.

It has been discovered that, between packages that are square or nearly square in shape (aspect ratio of package height to width of approximately <NUM>) and packages that are rectangular but not square in shape, consumers prefer the non-square packages, for reasons that are not thoroughly understood but are believed to relate to perceived convenience of pocketability and/or discreet carry. Accordingly, it may be desired to configure the pad and the package such that the closed package with the contained pad is rectangular in shape and has an aspect ratio of height H to width W (see <FIG>) of <NUM> to <NUM>, more preferably <NUM> to <NUM>, and even more preferably <NUM> to <NUM>.

In order to maximize user convenience, it may be desired that a folded pad 10a, folded as described above, be placed within the package with a main fold nose <NUM> disposed closest the package opening or top of the package (when the package is in an opened configuration) as suggested in <FIG>. Placing a main fold nose <NUM> relative the package opening in this orientation presents the user with a single edge of the folded product that she can quickly and easily visually and/or tactilely identify, for easy and quick grasping of the entire pad, e.g., between a thumb and forefinger, and removal from the package. By contrast, when multiple edges of the folded pad are presented in the opening, user effort grasping and removing the pad from the package may require more slightly more concentration and/or effort. It has been discovered that users substantially prefer the former configuration, for this reason, and also for the reason that users perceive that this configuration of the pad within the package makes the pad more impervious to contamination.

Another feature that may be desired to improve user convenience is to impart contrasting colors or other visible characteristics to the respective outside visible surfaces of the folded pad 10a and the inside surfaces of the package material, thereby providing a visual contrast between the inside surfaces of the opened package and an outer surface of the pad as contained therein, visible immediately after the package is opened. This feature helps the user quickly visually identify the pad within the package for grasping and removal. Visual contrast may be imparted by any suitable techniques including tinting, pigmenting or printing the materials of the pad backsheet, the release film or paper, the package material, or any combination thereof. Herein, a "visual contrast" between colors or shades of two respective materials means that an ordinary observer having <NUM>/<NUM> vision (natural or corrected) and no substantial color vision deficiency, in normal office lighting conditions appropriate for desktop work, can perceive a contrast between the color(s) on the outside of the folded pad in the package, and the color(s) of the inside of the package material, with the package in an opened condition. Alternatively, for relatively close colors or shades, a "visual contrast" is identified when the value of delta E* determined through the Visual Contrast method below is equal to or greater than <NUM>. For enhanced visual contrast, it may be preferred that the value of delta E* be equal to or greater than <NUM>. Alternatively, where decorative designs are visibly present on one or both the outside of the folded pad as contained in the package, and the inside of the package material with the package in opened configuration, a "visual contrast" is identified when a design is visibly present on one but not the other, or when designs are visibly present on each but the designs differ in any visible respect.

It has been learned that one or more of the process steps described below may be advantageous for imparting product features described above, and may provide additional advantages in manufacturing efficiency, reliability and quality assurance. Referring now to <FIG>, a process for manufacturing a packaged, folded feminine hygiene article is schematically depicted.

Starting at the top left of the figure, feminine hygiene pads <NUM> may be received from a converting line in configuration (I) in substantially finished condition, and with their longitudinal axes oriented in the machine direction MD. At the beginning of the process, pads <NUM> may have yet to have had backsheet adhesive <NUM> (see <FIG> and <FIG>) applied. Pads <NUM> may include wings <NUM>, as previously described. Pads <NUM> may be conveyed from the converting line to a wing folding unit <NUM>, which folds wings <NUM> (along, e.g., side longitudinal fold lines <NUM>, see <FIG>) over the wearer-facing/topsheet surfaces of the pads <NUM>, from which they emerge in configuration (II) with the wings <NUM> folded over. (A more detailed example of a depiction of a pad as it would appear in configuration (II) appears in <FIG>.

In configuration (II), the pads may be conveyed to a wings coversheet application unit <NUM>. The wings coversheet application unit <NUM> may be configured to receive wings coversheet stock from a supply roll <NUM> (which may be a roll of polymeric film or paper bearing an adhesive release surface or coating), cut it into individual wings coversheets <NUM>, apply deposits of backsheet adhesive thereto, and place the individual wings coversheets <NUM> bearing the adhesive over the folded wings <NUM>. Upon contact between the wings coversheet <NUM> and the folded over, outward-facing surfaces of the wings, the adhesive applied to the wings coversheet <NUM> can adhere and effectively transfer to the wings, so as to become a first portion of backsheet adhesive <NUM> deposited on the wings (see, e.g., <FIG> and <FIG>) and later remain in place on the wings when a user peels away the coversheet <NUM> in preparation to apply the pad to underwear. Prior to use, the wings coversheet <NUM> may serve to cover the adhesive and prevent it from being contaminated or adhering to surfaces not intended by the user. In some examples, the process may be configured to apply the adhesive directly to the wings directly/initially, rather than to the wings coversheets <NUM>. The process can be configured such that the pads emerge from wings coversheet application unit <NUM> in configuration (III).

In configuration (III), the pads may be conveyed to a turn and repitch unit <NUM>. Unit <NUM> may be a single unit, or a combination of cooperating units configured to receive individual pads moving with their longitudinal axes oriented in the machine direction MD, rotate them <NUM> degrees such that their longitudinal axes are oriented in the cross direction CD, phase them (i.e., space them along the MD by a predetermined distance), and place them onto a continuous web of backsheet adhesive coversheet stock <NUM>. Unit <NUM> may also be configured to receive backsheet adhesive coversheet stock <NUM> from a supply roll <NUM> and place the rotated pads thereonto. Unit <NUM> may also be configured to apply a deposit of backsheet adhesive, either directly to the pads, or indirectly to the backsheet adhesive coversheet <NUM> stock, such that the adhesive applied to the backsheet coversheets can adhere and effectively transfer to outward-facing surfaces of the pads (e.g., the outward-facing surfaces of the pad backsheets), so as to become a second portion of backsheet adhesive <NUM> deposited on the pads (see, e.g., <FIG> and <FIG>) and later remain in place on the pads when a user peels away the backsheet adhesive coversheet <NUM> in preparation to apply the pad to underwear.

Backsheet adhesive coversheet stock <NUM> may be any polymeric film or paper material suitable for serving as a releasable coversheet for covering areas of the pad bearing backsheet adhesive <NUM>. Further, in many circumstances, it may be desired that coversheet stock <NUM> be a material that is quiet, i.e., does not generate substantial audible noise, when manipulated by a user (such as when she removes the backsheet adhesive coversheet 17a from the pad in preparation to apply the pad to underwear). For this reason, a relatively quiet polymeric film may be selected for the coversheet stock <NUM>. In some examples the film may be predominately polyethylene, of an average caliper no greater than <NUM> (<NUM>), prefererably no greater than <NUM> (<NUM>) and even more preferably no greater than <NUM> (<NUM>). Polyethylene-based films tend to be relatively quiet as compared with paper and with films based on other polymers. Other relatively quiet film materials might also be selected.

Backsheet adhesive coversheet stock <NUM> may be provided on the supply roll <NUM> with machine-direction-spaced separation perforations <NUM> already present, or alternatively, unit <NUM> may include a perforation unit (not specifically shown) that provides successive cross-direction lines of separation perforations <NUM> (or other suitable lines of weakness, such as scoring partially through the thickness of the backsheet adhesive coversheet stock), substantially uniformly spaced along the machine direction by distances approximately corresponding to the widths of the pads with wings folded. Spacing PS of separation perforations <NUM> along the coversheet stock <NUM> may include any desired margins beyond the pad widths, but in some circumstances, it may be desired that such margins be minimized for purposes of compactness and neatness of the completed folded pad product. Thus, in some examples it may be desired that machine-direction spacing PS of separation perforations <NUM> be no greater than <NUM> percent of the average width of the pads (wings, if present, folded), more preferably no greater than <NUM> percent of the average width of the pads, and even more preferably no greater than <NUM> percent of the average width of the pads. As a result, following completion according to the further process steps described below, the widths of the backsheet adhesive coversheets on the pad products will be, respectively, no greater than <NUM> percent of the average width of the pads (wings, if present, folded), more preferably no greater than <NUM> percent of the average width of the pads, and even more preferably no greater than <NUM> percent of the average width of the pads. It will be appreciated, however, that as a feature or result of the process steps described herein, in no case will the machine-direction spacing PS be less than <NUM> percent of the average width of the pads.

Additionally, in <FIG>, it can be observed that the individually oriented, spaced series of pads 10b in configuration (IV) may have, between them prior to folding, separation perforations <NUM> in the backsheet adhesive coversheet stock <NUM>. It may be appreciated that the above-described method and any variant thereof, that successively places pads <NUM> on backsheet coversheet stock with the pads' longitudinal axes oriented in the cross direction CD, enables the manufacturer to provide coversheet stock <NUM> having a cross-direction dimension that is less than the length (LP, see <FIG>) of the pads. To illustrate, referring to location (IVA) of <FIG>, it can be seen that coversheet stock <NUM> does not extend in the cross direction CD to the ends <NUM>, <NUM> of the pads, but rather, lies short of them. This feature of the process is another way to enable the manufacturer to provide for a smaller, neater folded pad configuration because no unused margins of coversheet stock material <NUM> extend past the ends <NUM>, <NUM> of the pads.

In configuration (IV), the series of pads 10b with adhered backsheet adhesive coversheet stock <NUM> may be conveyed to a folding unit <NUM>. Folding unit <NUM> may be configured to continuously fold the series of pads 10b into two, three, four or more sections (for example, along fold lines <NUM>, <NUM>, <NUM>, <NUM>; see <FIG>, <FIG>), resulting in a connected series of folded pads 10c (adhered to backsheet adhesive coversheet stock <NUM>), in configuration (V). Folding unit <NUM> may be configured such that in configuration (V), the connected series of folded pads 10c are imparted with, for example, one of the folding configurations schematically illustrated in <FIG>.

In configuration (V), the connected series of folded pads 10c may be conveyed to a separation unit <NUM>. Separation unit <NUM> may be configured to continuously and successively exert machine direction tensile force on the successive pads, perpendicular to and across the lines of the separation perforations <NUM>, causing the backsheet adhesive coversheet stock <NUM> to separate along the perforations <NUM>. This results in a series of separated, folded pads 10a, each of which includes a backsheet adhesive coversheet 17a. Following separation, the folded, separated pads may be conveyed to a packaging phasing unit <NUM> configured to space the folded pads apart from one another along the machine direction, by a predetermined distance suitably selected for individual packaging as will be described below.

In some examples, referring to <FIG>, separation unit <NUM> may include two successive pairs of opposing separation rollers including an upstream pair 307a and a downstream pair 307b. Each respective pair of separation rollers 307a, 307b may be configured to operate without conveyor belts (whereby the pads 10c, 10a pass directly through the nip between each pair of rollers), or with respective corresponding, respective upstream and downstream pairs of upper and lower conveyor belts 307c, 307d cycling about each of the rollers (whereby the pads pass between the respective upper and lower belts). Upstream separation roller pair 307a may be operated such that their circumferential roller surfaces move at a tangential/linear velocity V1. Downstream separation roller pair 307b may be operated such that their circumferential roller surfaces move at a tangential/linear velocity V2. To effect separation of successive pads, the system may be configured and operated such that V2 is greater than V1. As each connected pad in the series 10c emerges from the nip or space between pair 307a and enters the nip or space between pair 307b moving at a greater velocity, friction between the pad and pair 307b, or between the pad and belts 307d, increases machine direction tension in the pad between roller pairs 307a, 307b, and causes each, leading, exiting folded pad 10a to separate from the incoming/trailing series of pads 10c, along the separation perforations <NUM>.

From the foregoing description it will be appreciated that the average width of the backsheet adhesive coversheets 17a on the separated folded pads 10a will be approximately equal to the spacing PS between the separation perforations <NUM> as shown in <FIG>. Thus, according to the description above, it may be desired that average width of the adhesive coversheets 17a be less than <NUM> percent, more preferably less than <NUM> percent, and even more preferably less than <NUM> percent (and in all cases at least <NUM> percent) of the width of the pads. For purposes of identifying presence of this feature and eliminating uncertainty resulting from variance in wing portion folding locations, the width of a pad is the greatest width of any portion of the absorbent layer <NUM> or absorbent core component disposed between the topsheet and backsheet. For purposes herein, averages may be calculated after measurements of adhesive backsheet coversheets and absorbent layer/core components of <NUM> examples of the product in question.

In view of the foregoing process description, the configuration of the separation perforations <NUM> may be important to efficient operation of the process as well as appearance of the resulting product. It may be desired that the separation perforations <NUM> through the coversheet stock <NUM> are not so extensive as to unacceptably compromise the tensile strength of the coversheet stock <NUM>, i.e., its ability to withstand ordinary machine direction operating tension in the line upstream of the separation unit <NUM>. If the separation perforations <NUM> are too extensive, the coversheet stock <NUM> may be vulnerable to premature, unwanted separation in processes upstream of the separation unit <NUM>, which can necessitate line shutdown. On the other hand, it may be desired that the coversheet stock separate easily, neatly and cleanly in separation unit <NUM>, so as to provide for smooth, even and uninterrupted conveyance of the pads through the separation unit <NUM> and the remainder of the line downstream, and provide a neat finished appearance to the separated side edges of the individual backsheet adhesive coversheets 17a, such that the edges have a relatively smooth, not jagged appearance to the naked eye.

Referring to <FIG>, separation perforations <NUM> may be substantially uniformly dimensioned and spaced to provide for smooth and even separation. The perforations may be created mechanically, e.g., by use of a perforating die, or thermally, e.g., by use of a suitably selected and tuned laser. The perforations may penetrate the film entirely, or only partially, to an extent sufficient to propagate an orderly separation of the file along the perforations. Separation perforations <NUM> have an average length PL in the cross direction CD, an average separation distance PSD in the cross direction CD, and an average perforation width PW in the machine direction MD. For purposes of balancing the needs for preserving suitable tensile strength in coversheet stock <NUM> upstream of the separation unit <NUM>, providing for efficient separation of pads in separation unit <NUM>, and providing for backsheet adhesive coversheets 17a with neatly separated edges in the finished product, it may be desired to configure perforating equipment such that perforations <NUM> have the following ranges of dimensions and ratio:.

It will be appreciated that a sufficiently magnified plan view of separated side edges of backsheet adhesive coversheets 17a will approximately reflect such dimensions and ratio. Referring to <FIG>, a backsheet adhesive coversheet 17a processed according to the steps described herein (including such perforation step) will have a side edge oriented in the cross direction, having an appearance with features having similarities to those shown in <FIG>. There will be relatively neat edges 18b having cross direction dimensions approximately corresponding to length PL where the perforations were present (relatively easily identifiable and measurable with aid of suitable magnification equipment provided/combined with linear distance measuring aids), and tabs 18c where unperforated portions were present between the perforations, the distal ends of tabs 18c evidencing strain of the uncut portions of the film in the machine direction, to the point of failure of such portions of the film. The separation process imparts the tabs 18c with somewhat irregular lengths and irregularly-shaped distal end edges. Despite these irregularities, however, average lengths PSD and ratios average PL/(average PL + average PSD), or the two in combination, within the ranges set forth above, will result in relatively small and/or closely spaced tabs 18c that are not highly noticeable to the naked eye, retaining a neat appearance for the side edges of the backsheet adhesive coversheet 17a. For purposes herein of determining average values for PL and PSD for a given product, <NUM> examples of backsheet adhesive coversheets from <NUM> examples of the product in question are measured, each along a randomly-selected sample portion of the edge in question, <NUM> in length. Averages of the <NUM> measurements for each value are then calculated.

Following separation of the series of pads 10c into individual folded pads in separation unit <NUM>, the individual folded pads may be conveyed to a packaging phasing unit <NUM>, configured to receive the pads and reposition/space them apart along the machine direction by an average predetermined distance suitable for individual packaging described as follows. Suitably spaced, individual folded pads 10a then emerge from packaging phasing unit <NUM> in configuration (VI) as shown in <FIG>.

In configuration (VI), the individual folded, spaced pads 10a may be conveyed to a flow-wrap unit <NUM>. Flow-wrap unit <NUM> may be configured to receive package film <NUM> from a package film supply roll <NUM>. In some examples the package film may be predominately polyethylene, of an average caliper no greater than <NUM> (<NUM>), prefererably no greater than <NUM> (<NUM>) and even more preferably no greater than <NUM> (<NUM>). Referring to <FIG> in conjunction with <FIG>, package film <NUM> already bearing pre-applied flap stickers 60d overlying pre-formed package opening cuts or perforations 54a in the film <NUM>, may be received by flow-wrap unit <NUM>. Alternatively, package film <NUM> may be received already bearing pre-applied flap stickers, but the film may yet to have package opening cuts or perforations 54a provided; and flow-wrap unit <NUM> may include or be preceded by a package film process unit <NUM> that provides package opening cuts or perforations 54a in package film <NUM>. Alternatively, package film process unit <NUM> may be configured to perform either or both of application of flap stickers 60d to the package film <NUM>, and provision of package opening cuts or perforations 54a in the package film <NUM>.

Package opening cuts or perforations 54a may be intermittent perforations or continuous cuts that penetrate substantially or all of the entire thickness/caliper of the package film <NUM> along the intended path of separation. A supplier of pre-cut package film, or the manufacturer of the product who performs such perforating or cutting, may be provided advantage by application of flap stickers 60d to the film prior to perforating or cutting. Perforating or cutting may be performed continuously using roller-based die-cutting equipment, and the presence of stickers 60d makes it unnecessary to adjust the equipment such that the die cutting blade edges contact an opposing anvil roller to effect a cut through substantially the entire caliper or thickness of the film. Rather, previously-placed flap stickers 60d on the film <NUM> can effectively provide relatively soft "anvil" surfaces against which the die cutting blades operate. Clearances in the cutting equipment may be adjusted such that the die-cutting blades substantially penetrate/cut through the film <NUM>, but not the flap stickers. In this manner, die cutting blade life may be extended because the die-cutting blade edges are not required to contact a relatively hard surface of an opposing anvil roller.

A continuous cut 54a in the film along the intended opening edge <NUM>, in contrast to intermittent perforations, may provide a benefit for the consumer/user in that no tearing of package film <NUM> (at uncut or unperforated portions between perforations) is required to open the package, thereby generating less noise by opening the package.

As it continuously intakes package film <NUM>, flow-wrap unit <NUM> also intakes the spaced (phased), individual folded pads 10a and successively disposes them in contact with the film along pre-determined (phased) intervals wherein the pad machine direction spacing corresponds and is registered with the film such that each pad is substantially evenly disposed/aligned between side crimp/seal/cut lines along the cross direction CD of the film, and between package bottom and top fold lines <NUM> and <NUM>. Such disposition is illustrated by way of example by pad disposition location PDL shown in <FIG>. Referring to <FIG>, flow-wrap unit <NUM> may be configured to then continuously wrap package film <NUM> over and about the succession of advancing pads 10a (e.g. via plow folding equipment). Referring again to <FIG>, package film <NUM> may be provided with seam margins 19a of extra film material extending (in the cross direction) outboard of seam margin lines <NUM>, to provide material to create a continuous machine-direction seam <NUM> joining the machine-direction edges of the package film <NUM> after it is wrapped about the pads 10a. The flow-wrap unit <NUM> may include or be accompanied by equipment for forming the seams via use of adhesive, via thermal fusion of the package film, or a combination thereof, along the seam margins 19a. The seaming equipment may be configured to form a continuous machine-direction fin seam (such as shown in cross section, by way of example, in <FIG> (seam <NUM>)), or alternatively, an overlap seam (such as shown in cross section, by way of example, in <FIG> (seam <NUM>)). As previously noted in some examples it may be desired that attachment between the joined sections forming back panel <NUM>, at seam <NUM>, whether effected by adhesive or by welding/fusion of the film, be intermittent or discontinuous and may have spaced intervals of attachment, rather than being continuous, along seam <NUM>. This may be desired to allow venting of air from within the finished package upon compression of the package, such as may occur in processes downstream of package formation, reducing chances that the package will burst open along seams or along the flap closure such as upon compression of the completed package.

A continuous series of flow-wrapped pads 10d emerge from the flow-wrap unit <NUM> in configuration (VII), also depicted by way of example, in cross section, in <FIG>. In configuration (VII), the series 10d may be conveyed to a package crimp sealing and cutting unit <NUM>. Package crimp sealing and cutting unit <NUM> may be configured to continuously receive the series 10d and then, at intervals corresponding to side crimp/seal/cut lines <NUM> (see <FIG>) crimp the package film <NUM> to form front and rear panels <NUM>, <NUM> together, adhere or fuse the package film of the respective panels to form cross direction side seams <NUM> (illustrated in, e.g., <FIG> and <FIG>) and cut the individual packages apart between successive trailing and leading portions of the seamed film material. Individually packaged pads 10e, in configuration (VIII), emerge from the package crimp sealing and cutting unit <NUM>, and may then be conveyed to a stacker (not shown) for controlled collection, orderly stacking and further packaging of quantities of individual packages, as desired. Adhesion or fusion of the package film of the front and rear panels to form side seams <NUM>, and/or cutting between successive leading and trailing packages, may be effected by direct, localized application of heat, ultrasonic energy or any other mechanism suitable to effect localized joining of the film of the front and rear panels. In some examples, seaming and cutting may occur simultaneously, via, e.g., a heated, appropriately shaped knife or die.

In some examples, rather than cutting the individual packages apart entirely as suggested in <FIG>, as suggested in <FIG>, unit <NUM> may be configured to create package separation perforations 19a between the formed seams of respective leading and trailing packages, as they pass through the unit, resulting in a continuous chain 10f of individual packages held together by the uncut portions of film within/along the paths of the package separation perforations between the respective package side seams of adjacent leading and trailing packages. This provides a chain of packages 10f that may be gathered by rolling, or folding or festooning with each other in, e.g., accordion-fashion, in a desired quantity, for a desired alternative mode of packaging and/or dispensation. Packages supplied in this mode may be separated from each other by tearing along the package separation perforations 19a.

It is also contemplated that processes by which individual pads are flow-wrapped and envelope packages are formed thereabout, described above, may be applied in other examples wherein the folded pads are conveyed into flow wrapping unit <NUM> with their longitudinal axes oriented in the machine direction MD, rather than in the cross direction CD as described above. The resulting individually packaged pad will appear in the package with one side edge exposed at the access opening when the package is opening, and the other side edge within the package proximate the opposite, closed end of the package.

The color difference measurement is based on the CIE L*a*b* color system (CIELAB). A flatbed scanner capable of scanning a minimum of <NUM> bit color at <NUM> dpi and has manual control of color management (a suitable scanner is an Epson Perfection V750 Pro from Epson America Inc. , Long Beach CA) is used to acquire images. The scanner is calibrated against a color reflection target compliant to ANSI method IT8. <NUM>/<NUM>-<NUM> using color management software (a suitable package is MonacoEZColor available from X-Rite Grand Rapids, MI) to construct a scanner profile. The resulting calibrated scanner profile is opened within an imaging program that supports sampling in CIE L*a*b* (a suitable program is Photoshop S4 available from Adobe Systems Inc. , San Jose, CA) to measure bonded and unbonded areas.

Turn on the scanner for <NUM> minutes prior to calibration. Place the IT8 target face down onto the scanner glass and close the scanner lid. Open the MonacoEZColor software and select acquire image using the Twain software included with the scanner. Within the Twain software deselect the unsharp mask setting and any automatic color correction or color management options that may be included in the software. If the automatic color management cannot be disabled, the scanner is not appropriate for this application. Acquire a preview scan at <NUM> dpi and <NUM> bit color. Insure that the scanned image is straight and first outer surface facing side-up. Crop the image to the edge of the target, excluding all white space around the target, and acquire the final image. The MonacoEZColor software uses this image to compare with included reference files to create and export a calibrated color profile compatible with Photoshop. After the profile is created the scan resolution (dpi) can be changed, but all other settings must be kept constant while imaging samples.

Provide respective samples of each layer <NUM> by <NUM> square. Precondition the samples at about <NUM> ± <NUM> C° and about <NUM>% ± <NUM>% relative humidity for <NUM> hours prior to testing.

Open the scanner lid and place the first sample onto the scanner glass with the first outer surface facing the glass. Cover the sample with the white background (in this test method white is defined as having L* > <NUM>, -<NUM> < a* < <NUM>, and -<NUM> < b* < <NUM>) and close the lid. Acquire and import a scan of the first sample into Photoshop at <NUM> dpi and <NUM> bit color. Assign the calibrated scanner profile to the image and change the mode to Lab Color ("Lab Color" in Photoshop corresponds to the CIE L* a* b* standard). Select the "eyedropper" color selection tool. Set the sampling size of the tool to include as many pixels as possible within an area of the sample <NUM> by <NUM> square. Using the eyedropper tool measure and record L*a*b* values in <NUM> different <NUM> by <NUM> square areas (not having apertures) in the sample image. Average the <NUM> individual L*a*b* values and record as L1, a1, and b1 respectively.

Repeat the steps in the paragraph above for the second sample, and record the averaged values as L2, a2 and b2. Calculate and report the color difference (delta E*) between the bonded and unbonded areas using the following equation: <MAT> and report to the nearest <NUM> units. A total of three substantially identical samples of each layer are measured for each sample set. Average the three delta E* values and report to the nearest <NUM> unit.

Claim 1:
A product comprising a feminine hygiene pad (<NUM>) in a folded configuration provided within an individualized envelope package (<NUM>) having a front panel (<NUM>) and a rear panel (<NUM>);
wherein the pad in the folded configuration is folded separately of the envelope package and is entirely contained within the package,
wherein the envelope package has a rectangular shape and comprises:
a section of polymeric film (<NUM>);
a pair of oppositely-disposed, substantially straight and substantially parallel side seams (<NUM>) along which respective portions of the polymer film forming the front panel (<NUM>) and rear panel (<NUM>) are attached to each other, the seams having a length;
a top edge extending from one side seam to the other when the package is in a closed configuration;
a closure flap (<NUM>), having a proximal portion proximate the top edge, and terminating at a distal edge (<NUM>), wherein:
the package is configured to create an access opening upon lifting of the closure flap at the distal edge, the access opening having an opening edge (<NUM>),
the closure flap (<NUM>) overlaps the opening edge (<NUM>); and
the closure flap may be lifted to create the access opening while allowing material along the side seams to remain unseparated along a majority, substantially all, or all of respective lengths of the side seams;
wherein the closure flap comprises a flap sticker (60d) that covers and overlaps the opening edge (<NUM>);
wherein the opening edge (<NUM>) has a path length, and the flap sticker (60d) overlaps and covers the opening edge over a majority of the path length, preferably the entirety of the path length;
wherein the opening edge (<NUM>) is formed by perforating or cutting a portion of the polymeric film forming a front panel (<NUM>) of the envelope package along a path of separation defining the opening edge, and the overlapping flap sticker (60d) with adhesive (60e) thereon holds the flap in a closed position.