Patent ID: 12239515

DETAILED DESCRIPTION

All ranges are inclusive and combinable. The number of significant digits conveys neither limitations on the indicated amounts nor on the accuracy of the measurements. All numerical amounts are understood to be modified by the word “about” unless otherwise specifically indicated.

The term “absorbent articles”, as used herein, include disposable diapers, sanitary napkins, panty liners, incontinence pads, interlabial pads, breast-milk pads, sweat sheets, animal-use excreta handling articles, animal-use diapers, and the like.

The term “component” of an absorbent article, as used herein, refers to an individual constituent of an absorbent article, such as a topsheet, secondary layer, acquisition layer, liquid handling layer, absorbent core or layers of absorbent cores, backsheet, and outer cover.

Three Dimensional Nonwoven

As used herein, the term “nonwoven” or “nonwoven” refers to a web having a structure of individual fibers or threads which are interlaid, but not in a repeating pattern as in a woven or knitted fabric, which do not typically have randomly oriented fibers. Nonwoven or fabrics have been formed from many processes, such as, for example, meltblowing, spunbonding, hydroentangling, airlaid, wetlaid, through-air-dried paper making processes, and bonded carded web processes, including carded thermal bonding. The nonwoven can comprise unbonded fibers, entangled fibers, tow fibers, or the like. Fibers can be extensible and/or elastic, and may be pre-stretched for processing. Fibers can be continuous, such as those produced by spunbonded methods, or cut to length, such as those typically utilized in a carded process. Fibers can be bicomponent, multiconstituent, shaped, crimped, or in any other formulation or configuration known in the art for nonwoven and fibers. In general, the fibers can be bondable, either by chemical bond (e.g. by latex or adhesive bonding), pressure bonding, or thermal bonding. If thermal bonding techniques are used in the bonding process described below, a certain percentage of thermoplastic material, such as thermoplastic powder or fibers can be used.

The present disclosure provides a three dimensional nonwoven suitable for a component such as a topsheet and an outer cover, an outermost sheet, of an absorbent article.FIGS.1and2show a plan view of a three dimensional nonwoven of the present disclosure and a magnified plan view thereof, respectively.FIG.3shows a partial cross-section view of the nonwoven ofFIG.1. Referring toFIGS.1-3, a three dimensional nonwoven30of the present disclosure comprises at least one protruded area2which comprises a first area21having a first light reflectance and a second area22having a second light reflectance which is different from the first light reflectance.

The three dimensional nonwoven30further comprises at least one recess8comprising a third area4, the third area4being adjacent to the second area22. In one embodiment, the second area22is located along at least a part of a periphery of the recess8. The three dimensional nonwoven30may comprise a plurality of recesses8, as shown inFIG.1. The recess8may be substantially surrounded by the protruded area2. The term “substantially surrounded” herein intends to mean that at least 80% of a periphery of the recess is surrounded by the protruded area. In one embodiment, the three dimensional nonwoven30comprises a plurality of recesses8, each recess8being surrounded by the protruded area2as shown inFIG.1. In another embodiment, the three dimensional nonwoven30comprises a plurality of protruded areas2, each protruded area2being surrounded by the recess8.

The third area4may have a third light reflectance and a third thickness.

In some embodiments, the three dimensional nonwoven of the present disclosure is a carded nonwoven such as a carded air-through nonwoven.

The three dimensional nonwoven of the present disclosure may comprise one or more layers.

In some embodiments, the three dimensional nonwoven comprises at least two layers each of which remains as a discrete layer which may be attached to each other by, for example, thermal bonding, compression, adhesive bonding or any combination thereof. The first layer and the second layer in the nonwoven may be bonded to each other without using chemicals such as adhesive and latex.

In some embodiments, the three dimensional nonwoven comprises a unitary structure. A unitary structure herein intends to mean that although it may be formed by several sub-layers that have distinct properties and/or compositions from one another, they are somehow intermixed at the boundary region, so that, instead of a definite boundary between sub-layers, it would be possible to identify a region where the different sub-layers transition one into the other. Such a unitary structure is typically built by forming the various sub-layers one on top of the other in a continuous manner, for example using air laid or wet laid deposition. Typically, there is no adhesive used between the sub-layers of the unitary material. However, in some cases, adhesives and/or binders can be present although typically in a lower amount that in multilayer materials formed by separate layers.

The three dimensional nonwoven may comprise thermoplastic fibers. The nonwoven may comprise any suitable types of thermoplastic fibers, such as polypropylene fibers, other polyolefins, other polyesters besides PET such as polylactic acid, thermoplastic starch-containing sustainable resins, other sustainable resins, bio-PE, bio-PP, and Bio-PET. The nonwoven may comprise any other suitable types of fibers such as viscose fibers, rayon fibers, or other suitable nonwoven fibers, for example. These fibers may have any suitable deniers or denier ranges and/or fiber lengths or fiber length ranges. The three dimensional nonwoven may comprise bicomponent fibers. Bicomponent fibers can have a sheath and a core. The sheath and the core may also comprise any other suitable materials known to those of skill in the art. The core/sheath composite fibers may comprise a core component comprising a resin and a sheath component comprising a thermoplastic resin having a melting point of at least about 20° C. lower than a melting point of the resin of the core component. The sheath and the core may each comprise about 50% of the fibers by weight of the fibers, although other variations (e.g., sheath 60%, core 40%; sheath 30%, core 70% etc.) are also within the scope of the present disclosure. The bicomponent fibers or other fibers that make up the first and/or second layers may have a denier in the range of about 0.5 to about 6, about 0.75 to about 4, about 1.0 to about 4, about 1.5 to about 4, about 1.5 to about 3, about 1.5 to about 2.5, or about 2, specifically including all 0.1 denier increments within the specified ranges and all ranges formed therein or thereby. Denier is defined as the mass in grams per 9000 meters of a fiber length. In other instances, the denier of the fibers of the first layer may be in the range of about 1.5 denier to about 6 denier or about 2 denier to about 4 denier and the denier of the fibers of the second layer may be in the range of about 1.2 denier to about 3 denier or about 1.5 denier to about 3 denier, specifically reciting all 0.1 denier increments within the specified ranges and all ranges formed therein or thereby. Bicomponent fibers can be a side-by-side type fibers.

In a form, the basis weight of the three dimensional nonwoven may be appropriately selected depending on the nonwoven application. For the nonwoven of the present disclosure as a topsheet or an outer cover of an absorbent article, a basis weight of the nonwoven may be from about 15 gsm (g/m2) to about 75 gsm, or from about 20 gsm to about 75 gsm, or from about 30 gsm to about 65 gsm. All other suitable basis weight ranges for the nonwoven are within the scope of the present disclosure. Accordingly, the basis weight of the nonwoven may be designed for specific product requirements.

Protruded Area

Referring toFIGS.1-3, the three dimensional nonwoven30comprises at least one protruded area2providing a three dimensional profile to the nonwoven30. The protruded area2comprises a first area21having a first light reflectance and a second area22having a second light reflectance which is different from the first light reflectance. The difference between the first light reflectance and the second light reflectance may be no less than about 6, no less than about 8, or no less than about 10, as measured according to Light Reflectance Test. In one embodiment, the second light reflectance is greater than the first light reflectance. The second light reflectance may be no less than about 100, or no less than about 105 or no less about 108, as measured according to Light Reflectance Test. Without wishing to be bound by theory, the protruded area2has a first area21and a second area22which have different light reflectances, so that light reflectance contrast between the first area21and the second area22enhances visual perception of three dimensional structure of the nonwoven.

In one embodiment, the second area22is a highly heat-fused in such a way that the second area22is heat-fused in a higher extent than the first area21in the protruded area2. When the second area22is highly heat fused, the second area22has a light reflectance higher than the first area21as the second area22has a less pore area where no fiber exists than the first area21in a unit area.

Referring toFIGS.1and3, the second area22may be located on a wall of protruded area2. When the second area22is located on the wall of the protruded area it can increase a contrast effect between the first area21and the second area22with little or no impact on the nonwoven softness. The second area22may be located only on a wall of protruded area2, and is not located on a top of the protruded area22.

The protruded area2may be continuous extending in one or more directions in the three dimensional nonwoven30, as shown inFIG.1. In one embodiment, the protruded area2may be continuous extending in one direction, for example substantially along a machine direction, a length direction of the nonwoven. In another embodiment, the three dimensional nonwoven of the present disclosure comprises a plurality of discrete protruded areas22.

The second area22may be formed along at least part of a periphery of protruded area2. The second area22may be formed along at least part of a periphery of the protruded area2in a length direction of the protruded area2in such a way that the length of the second area22is shorter than the length of the protruded area2, referring toFIG.1. The term “length direction” in this context intends to mean a direction along which the protruded area extends. The protruded area2may have the second area22along the entire periphery of protruded area2.

The first area21has a first thickness and the second area22has a second thickness different from the first thickness. The second thickness may be no greater than about 100 μm, or no greater than about 80 μm, as measured according to Thickness Test. The first thickness may be no less than about 500 μm, or no less than 600 μm, as measured according to Thickness Test.

The second area may have a length no less than about 3 mm, no less than about 4 mm, or no less than 5 mm, measured according to Light Reflectance Test. The second area may have an area no less than about 2 mm2, or no less than about 2.5 mm2, measured according to Light Reflectance Test.

The protruded area may form a pattern. A pattern formed by the protruded area may be any shape of pattern, for example, a shape of one or multiple linear lines or curved lines, a circles, an ellipse, a triangle, a polygon, a flower, a cloud, and the like. The pattern may be a regular, homogeneous and uniform pattern or an irregular, non-uniform and non-homogeneous pattern. In some embodiments, nonwoven of the present disclosure comprises a plurality of protruded areas, wherein the protruded areas are not necessarily in the same shape or size. That is, one protruded area may differ from another protruded area in the nonwoven of the present disclosure. Patterns may be various shapes and/or various sizes. The nonwoven of the present disclosure may have uniform protruded patterns.

The protruded area may coordinate with graphics, indicia, printing, inks, color, and/or patterned adhesives, for example, located in the nonwoven or in another component of an absorbent article when it is used as a component of an absorbent article.

Recess

Referring toFIGS.1-3, the three dimensional nonwoven30further comprises at least one recess8comprising a third area4, the third area4being adjacent to the second area22. A recess herein intends to mean an area having a lower height than the protruded area including a land area which is not concaved, and a concaved area.

The third area4has a third light reflectance. The third light reflectance may be different from the second light reflectance of the second area22. The difference between the second light reflectance and the third light reflectance may be no less than about 6, no less than about 8, or no less than about 10, as measured according to Light Reflectance Test. In one embodiment, the second light reflectance is greater than the third light reflectance.

The recess8may comprise a plurality of elements which may comprise apertures, embosses or a combination thereof. In one embodiment, the recess8comprises a plurality of apertures as shown inFIGS.1-3.

The elements may be in any of circular, oval, hour-glass shaped, star shaped, polygonal and the like, and combinations thereof. Polygonal shapes include, but are not limited to triangular, quadrilateral, hexagonal, octagonal or trapezoidal. In one embodiment, elements are circular. In another embodiment, elements are an oval shape. Elements may have a size in a range of about 0.1 mm2-about 3 mm2, or in a range of about 0.2 mm2-about 2 mm2, or in a range of about 0.3 mm2-about 1 mm2. The recess may have elements having the same size and/or shape. The recess may have elements having different sizes and/or shapes.

The recess may form a pattern. Descriptions of a pattern stated with respect to protruded area, supra are applicable to the pattern formed by the recess.

Nonwoven Manufacturing Process

The three dimensional nonwoven of the present disclosure may be made by any suitable methods known in the art.

The nonwoven may be manufactured via a process comprising the steps of: (a) providing a precursor nonwoven; and (b) subjecting the precursor nonwoven to a deformation forming unit to form a protruded area(s) to obtain a three dimensional nonwoven, the three dimensional nonwoven comprising at least one protrusion and at least one recess wherein the protrusion comprises a first area having a first light reflectance and a second area having a second light reflectance which differs from the first light reflectance, and the recess comprises a third area having a third light reflectance.

The precursor nonwoven may be carded webs such as parallel webs, semi-random webs, random webs, cross-webs, criss-cross webs, and the like, air-laid webs, wet-laid webs, and spunbond webs, and the like.

Deformation of precursor nonwoven to form a three dimensional nonwoven can be conducted according to any conventionally known nonwoven deformation method. An exemplary deformation equipment is a pair of rolls comprising a first roll and a second roll. Referring toFIG.6, precursor nonwoven20may be deformed by passing it through a nip502formed by a pair of rolls500having two intermeshing rolls504and506, to form a three dimensional nonwoven30. At least one of the rolls504and506may be heated.FIG.7shows a view of intermeshing engagement of portions of an exemplary first and a second rolls in the pair of rolls.

In one embodiment, referring to andFIGS.1and2andFIGS.6and7, a first roll504may create the protruded area2and the recess having a plurality of apertures6in the nonwoven30(in combination with the second roll).

A first roll504may create a protruded area2in the three dimensional nonwoven30(in combination with the second roll506) and a second roll506may create the recess8and apertures6and in the three dimensional nonwoven30(in combination with the first roll504). The first roll504may comprise at least one protrusion508extending radially outwardly from the first roll504. The first roll504may also comprise a plurality of concaves510formed in a radial outer surface of the first roll504. Each concave510may comprises a plurality of holes516.

The second roll506may comprise at least one convex512extending radially outwardly from the second roll506. Each convex512comprises a plurality of projections518which create apertures6in the three dimensional nonwoven30(in combination with the first roll504). The second roll506may also comprise at least one groove514formed in the radial outer surface of the second roll506. The grooves514in the second roll506may be configured to at least partially receive the protrusion(s)508, thereby creating the protruded area2in the nonwoven30. The groove514in the second roll506may be deep enough so that a peak of the protruded area2will not be compressed. Specifically, as the protrusion508engages into the groove514, there is sufficient depth left in the space between the surfaces in a radial direction so that the thickness of the substrate in peak of the protruded area2is greater than the thickness of the recess8. This feature provides protruded area2with a softer feel and a greater height compared to compressing the portions of the substrate forming the peak of the protruded area.

FIG.8AandFIG.8Bare schematic illustrations of exemplary intermeshing engagement of a protrusion508in a first roll504and a groove514in the second roll to form a protruded area2comprising a first area21and a second area22in accordance with the present disclosure.

In one embodiment, to create the second area22in the wall of the protruded area2, referring toFIG.8A, the groove514in the second roll506may be configured to at least partially receive the protrusion508in the first roll in such a way that a gap between a first sidewall of the protrusion508and a first sidewall of the groove514facing the first sidewall of the protrusion508is bigger than a gap between a second sidewall of the protrusion508and second sidewall of groove514facing the second sidewall of the protrusion508.

In another embodiment, to create the second area22in the wall of the protruded area2, at least a first sidewall of the protrusion508and a first sidewall of the groove514facing the first sidewall of the protrusion508have different slope angle, so that the first sidewall of the protrusion508and the first sidewall of the groove514are not parallel to each other and at least the side gap between the first sidewall of the protrusion508and the first sidewall of the groove514has inconsistent gap. One example of such a configuration is illustrated inFIG.8B.

The concave510in the first roll505may be configured with the convex512in the second roll506in such a way that the concave510and the holes516in the first roll504at least partially receive the convex512and the projections518in the second roll506thereby creating the recesses8and the apertures6in the three dimensional nonwoven30.

Absorbent Article

An absorbent article of the present disclosure comprises a skin-facing surface, a garment-facing surface, a liquid pervious topsheet, a liquid impervious backsheet, an absorbent core disposed between the topsheet and the backsheet, and a three dimensional nonwoven disclosed herein. In one embodiment, the liquid permeable topsheet comprises the three-dimensional nonwoven. In another embodiment, the three dimensional nonwoven of the present disclosure forms at least part of the garment-facing surface.

Absorbent articles will now be generally discussed and further illustrated in the form of a baby diaper1as exemplarily represented inFIG.9.FIG.9is a plan view of the exemplary diaper1in a flattened-out configuration with the taped ends opened and the garment-facing side turned up. An article that is presented to the user closed such as a training pant may also be represented flattened out by cutting it along its side waists. The absorbent article will typically have a front edge110, a back edge112and the longitudinally-extending lateral side edges113,114. The front edge110forms the edge of the front waist and the back edge112of the back waist, which together when worn by the wearer form the opening for the waist of the wearer. The lateral edges113,114can each form one of the leg openings. The absorbent article100notionally comprises a longitudinally centerline80dividing the article in a left side and a right side, and a perpendicular transversal centerline90disposed at half the length of the article as measured on the longitudinal centerline80, with both centerlines crossing at the center point C. The taped back ends42attached on the front of the diaper to such as a landing zone44.

Other layers of the absorbent article are better illustrated inFIG.10, which shows in cross-section in addition to the liquid permeable topsheet24and the backsheet26, an absorbent core28between the topsheet24and the backsheet26.

A suitable topsheet may be manufactured from a wide range of materials, such as porous foams, reticulated foams, apertured plastic films, woven materials, nonwoven materials, woven or nonwoven materials of natural fibers (e.g., wood or cotton fibers), synthetic fibers or filaments (e.g., polyester or polypropylene or bicomponent PE/PP fibers or mixtures thereof), or a combination of natural and synthetic fibers.

An optional acquisition and/or distribution layer (or system)54is represented inFIG.11together with other typical diaper components. The acquisition and/or distribution layer may comprise one layer or more than one layer. Typical acquisition and/or distribution layers may not comprise SAP as this may slow the acquisition and distribution of the fluid, but an additional layer may also comprise SAP if some fluid retention properties are wished.

The absorbent article may typically comprise a pair of partially upstanding barrier leg cuffs34having elastic elements35and elasticized gasketing cuffs32having elastic elements33substantially planar with the chassis. Both types of cuffs are typically joined to the chassis of the absorbent article typically via bonding to the topsheet and/or backsheet.

The absorbent article may comprise elasticized back ears40having a tape end42which can be attached to a landing zone44at the front of the article, and front ears46typically present in such taped diapers to improve containment and attachment.

Absorbent Core

As used herein, the term “absorbent core” refers to a component used or intended to be used in an absorbent article and which comprises an absorbent material and optionally a core wrap. As used herein, the term “absorbent core” does not include the topsheet, the backsheet and any acquisition-distribution layer or multilayer system, which is not integral part of the absorbent core. The absorbent core is typically the component of an absorbent article that has the most absorbent capacity of all the components of the absorbent article. The terms “absorbent core” and “core” are herein used interchangeably.

Referring toFIGS.9and10, the absorbent core28can absorb and contain liquid received by the absorbent article and comprise an absorbent material60, which may be cellulose fibers, a blend of superabsorbent polymers and cellulose fibers, pure superabsorbent polymers, and/or a high internal phase emulsion foam. The absorbent core28may comprise absorbent material free channels29, through which the top side56of the core wrap may be bonded to the bottom side58of the core wrap. The core wrap bonds27may at least persist as the absorbent core28swells upon liquid absorption and creates three dimensional channels at the wearer-facing surface of the article. Of course, this is entirely optional, the absorbent core may also not have bonded channels, or even unbonded channels. The absorbent material defines an absorbent material area8, which may be rectangular as show in inFIG.9, but it is also common to have a shaped area which is tapered in the area around the transversal centerline90.

The absorbent material comprises a liquid-absorbent material commonly used in disposable absorbent articles such as comminuted wood pulp, which is generally referred to as airfelt or fluff. Examples of other suitable liquid-absorbent materials include creped cellulose wadding; melt blown polymers, including co-form; chemically stiffened, modified or cross-linked cellulosic fibers; tissue, including tissue wraps and tissue laminates, absorbent foams, absorbent sponges, superabsorbent polymers (herein abbreviated as “SAP”), absorbent gelling materials, or any other known absorbent material or combinations of materials.

The absorbent material in the absorbent core can be any type. It can be an airfelt core comprising wood cellulose fibers such as pulp fibers mixed with SAP, or an airfelt-free core free from such cellulose fibers. Airfelt cores typically comprises from 40% to 80% of SAP. For absorbent cores comprising a relatively high proportion of SAP at least partially enclosed within the core wrap, the SAP content may represent in particular at least 80%, 85%, 90%, 95% and up to 100%, of superabsorbent polymer by weight of the absorbent material. The absorbent material may in particular comprise no or only small amount of cellulose fibers, such as less than 20%, in particular less than 10%, 5% or even 0% of cellulose fibers by weight of the absorbent material. The absorbent core may comprise an absorbent material comprising at least 80%, at least 90%, at least 95%, or at least 99% by weight of the absorbent core. The term “superabsorbent polymer” refers herein to absorbent material, which may be cross-linked polymer, and that can typically absorb at least 10 times their weight of an aqueous 0.9% saline solution as measured using the Centrifuge Retention Capacity (CRC) test (EDANA method WSP 241.2-05E). The SAP may in particular have a CRC value of more than 20 g/g, or more than 24 g/g, or of from 20 to 50 g/g, or from 20 to 40 g/g, or from 24 to 30 g/g. The SAP may be typically in particulate forms (superabsorbent polymer particles), but it not excluded that other forms of SAP may be used such as a superabsorbent polymer foam for example.

Backsheet

An absorbent article according to the present disclosure comprises a liquid impervious backsheet. The backsheet may be designed to prevent the exudates absorbed by and contained within the absorbent article from soiling articles that may contact the absorbent article, such as bed sheets and undergarments. The backsheet may be substantially water-impermeable. Suitable backsheet materials may include breathable materials that permit vapors to escape from the absorbent article while still preventing exudates from passing through the backsheet. The backsheet may comprise a liquid impermeable film. The backsheet may comprise a wetness indicator.

Outer Cover

An absorbent article according to the present disclosure may comprise an outer cover forming at least part of a garment-facing surface of the absorbent article. The outer cover may comprise a three dimensional nonwoven disclosed herein in such a way that a first side having protrusions of the substrate forms at least part of the garment-facing side of the article. When a backsheet comprises a liquid impermeable polymer film, the polymer film and the substrate disclosed herein may be disposed in a face to face relationship in such a way that the substrate is towards the garment-facing side of the article, and the film is towards an absorbent core of the article. The first layer is oriented outwardly relative to the article, so that the protrusions can be felt by the caretaker or a user feeling the garment-facing side of the article.

The absorbent article may also comprise other typical components, which are not represented, such as a back-elastic waist feature, a front elastic waist feature, transverse barrier cuff(s), a lotion application, etc.

Components of the disposable absorbent article described in this specification can at least partially be comprised of bio-sourced content as described in US 2007/0219521A1 Hird et al published on Sep. 20, 2007, US 2011/0139658A1 Hird et al published on Jun. 16, 2011, US 2011/0139657A1 Hird et al published on Jun. 16, 2011, US 2011/0152812A1 Hird et al published on Jun. 23, 2011, US 2011/0139662A1 Hird et al published on Jun. 16, 2011, and US 2011/0139659A1 Hird et al published on Jun. 16, 2011. These components include, but are not limited to, topsheet nonwovens, backsheet films, backsheet nonwovens, side panel nonwovens, barrier leg cuff nonwovens, super absorbent, nonwoven acquisition layers, core wrap nonwovens, adhesives, fastener hooks, and fastener landing zone nonwovens and film bases. In at least one embodiment, a disposable absorbent article component comprises a bio-based content value from about 10% to about 100% using ASTM D6866-10, method B, in another embodiment, from about 25% to about 75%, and in yet another embodiment, from about 50% to about 60% using ASTM D6866-10, method B. In order to apply the methodology of ASTM D6866-10 to determine the bio-based content of any disposable absorbent article component, a representative sample of the disposable absorbent article component must be obtained for testing. In at least one embodiment, the disposable absorbent article component can be ground into particulates less than about 20 mesh using known grinding methods (e.g., Wiley® mill), and a representative sample of suitable mass taken from the randomly mixed particles.

Test Methods

1. Light Reflectance Test

The Light Reflectance Test measures the amount of light reflected from a visually discernable area on the surface of the three-dimensional nonwoven illuminated by direct light at an incident angle of approximately 67 degrees. It is based on analysis of a calibrated grayscale digital image of the illuminated sample surface using an image analysis program (a suitable program is ImageJ v. 1.52, National Institute of Health, USA, or equivalent).

(1) Sample Preparation

To obtain a sample for measurement, lay a dry substrate raw material out flat and cut to an appropriate size for analysis.

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

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

A sample may be obtained from any location containing the visually discernible areas to be analyzed. An area may be visually discernable due to changes in texture, height, specular light reflectance, or thickness. Care should be taken to avoid folds, wrinkles or tears when selecting a location for sampling and analysis.

(2) Image Acquisition

Sample and calibration images were taken using a lab-built image acquisition system. The key components include a DSLR camera (Canon EOS 6D Mark 2) with a lens (EF 24-105 mm f/4L IS 2 USM lens, or equivalent), a non-reflective black background plate, and a bar light (Smart Vision Lights LHF 300, Muskegon, MI, or equivalent). The bar light is placed 700 mm away from the sample in the horizontal direction and 300 mm away from the sample in the vertical direction, such that the directed light has an angle of incidence of approximately 67 degrees. The sample is laid horizontally flat at the center of the black background plate, directly beneath and centered within the field of view of the camera mounted 800 mm directly above, rotated to maximize the amount of specular reflectance from the identified areas (e.g. melt lines), and an image is acquired. Next, acquire an image of a calibrated color standard target containing 24 standard color chips (ColorChecker Passport, available from X-Rite; Grand Rapids, MI, or equivalent) positioned at the same location as the sample and under the same imaging conditions. Lastly, acquire an image of a plain white background under the same lighting and imaging conditions. The camera's manual settings are set so that the image is properly exposed, such that there is no signal clipping in any of the color channels. Suitable settings might be a focal length of the camera set to 105 mm, ISO: 100, F stop: 8.0, Shutter speed: 1/15 sec. Using a standard 18% gray card (e.g., Munsell 18% Reflectance (Gray) Neutral Patch/Kodak Gray Card R-27, available from X-Rite; Grand Rapids, MI, or equivalent), the camera's white balance is custom set for the lighting conditions. Each image is properly focused, captured, and saved as a 24-bit RGB JPEG file. The resulting images must be at a resolution of at least 18 pixels/mm

(3) Image Calibration

The sample, color standard, and background image files are opened in the image analysis software. First, convert all three RGB images to CIELAB color space and extract only the L* channel image from each for further analysis. Next, use the background image to flatten the lighting gradient present in the sample and color standard images. Create a calibration curve using the measured average L* values from each of the six monochromatic grayscale chips in the image of the color standard and their reported true L* values provided with the color standard target. Lastly, apply the calibration curve transform to correct the L* pixel values in the sample image and distance calibrate the image.

(4) Light Reflectance Measurement

To measure the light reflectance of an area (e.g. the first area, the second area, the third area) begin by identifying the boundaries of three distinct adjacent areas. The boundary of an area is identified by visual discernment of differences in physical properties when compared to other areas within the sample. For example, an area boundary can be identified based by visually discerning a thickness or height difference when compared to another area in the sample. Differences in physical properties such as height, thickness, texture, or specular reflection of light can be used to discern area boundaries on either the physical sample itself, cross-sectional images, topography images, or light reflection images.

Referring toFIG.17, using the image analysis software, manually draw a line tracing an enclosed “region of interest” (ROI) along the identified boundary of the area having the greatest specular reflectance i.e., the second area22. Once the boundary of that region has been drawn, make two copies of the ROI and place one on either side of the initial ROI, within the identified boundaries of the two adjacent areas, i.e, an area21′ in the first area21, and area4′ in the third area4. The average L* values are measured from within each of the three ROIs and recorded as a light reflectance for each of the three individual areas to the nearest tenth. Additionally, measure and record the boundary ROI's area to the nearest 0.1 mm2and the maximum feret diameter to the nearest 0.1 mm The maximum ferret diameter is considered a ROI length. This procedure is repeated at two other identified replicate locations representing the first area21and the third area4and their individual light reflectances are measured and recorded accordingly. The arithmetic mean of the three recorded values from each of the three distinct areas is calculated and reported as their Reflectance Value to the nearest tenth. Additionally, calculate and report the average boundary ROI area and maximum feret diameter (ROI length).

2. Thickness Test

The Thickness Test measures the cross-sectional thickness of an identified sample area using an optical microscope equipped with a digital camera to capture an image. Linear distances within the captured image are measured using image analysis software appropriate for making calibrated distance measurements (a suitable software is ImageJ v. 1.52, National Institute of Health, USA, or equivalent).

(1) Sample Preparation

A sample for measurement is prepared according to (1) Sample Preparation under Light Reflectance Test, supra.

(2) Image Acquisition

Samples are mounted to a rigid plate such that the cross-sectioned edge is left unconstrained and unobstructed when viewed through the microscope. The mounted sample is placed beneath the objective and oriented such that the cross-sectioned edge is viewed face on. Reflected illumination from a directed light source is used to illuminate the sample. The image is focused at the cross-sectioned edge surface and a properly exposed digital image is captured. Additionally, an image of a calibrated ruler is captured in the same position and manner as the sample. The acquired digital images must have a resolution of at least 1 micron per pixel.

(3) Thickness Measurement

The acquired images are imported into the image analysis software and the sample image spatially calibrated against the certified ruler image. Spatial calibration is used to establish pixel size and allow for conversion to standard units. Using the image analysis software, the distance between the upper and lower sample surfaces at the cross-sectional edge surface and within each of the adjacent identified areas is measured and recorded. A total of five replicate thickness measurements are made on each of the identified areas from three replicate samples. The arithmetic mean of the five recorded measurements from each of the adjacent areas is calculated and each is reported as its thickness to the nearest micron.

EXAMPLES

Example 1. Nonwoven Preparation

35 gsm carded air-through nonwoven was prepared from 2 denier PET/PE core/sheath bicomponent fibers and used as precursor nonwoven.

Nonwoven 1

The obtained 35 gsm carded air-through nonwoven was put into a mechanical embossing-aperturing process illustrated inFIG.6using a pair of rolls shown inFIG.7to produce Nonwoven 1 having features shown inFIGS.1-3.

A protrusion508in a first roll504and a groove514in the second roll506to be engaged with each other had a configuration illustrated inFIG.8A. That is, a first sidewall of the protrusion508was parallel to a first sidewall of the groove514facing the first sidewall of the protrusion508, and a second sidewall of the protrusion508was parallel to a second sidewall of the groove514facing the second sidewall of the protrusion508, and the side gap between the first sidewall of the protrusion508and the first sidewall of the groove514was narrower than the side gap between the second sidewall of the protrusion508and the second sidewall of the groove514. The embossing-aperturing process formed a first area21and a second area22in the protruded area2.

Nonwoven running speed was about 25 meter/min. Temperatures of a first roll and a second roll were 83° C. and 73° C., respectively.

Nonwoven 2

Three dimensional nonwoven (Nonwoven 2) having features shown inFIGS.4and5was produced using the 35 gsm carded air-through nonwoven according to the process disclosed with respect to Nonwoven 1 above except for temperatures of a first roll and a second roll being 77° C. and 67° C., respectively.

Nonwoven 3

Nonwoven 3 having features shown inFIGS.11-13was produced using the 35 gsm carded air-through nonwoven.FIG.11is a plan view of Nonwoven3, andFIG.12is a magnified plan view of part of Nonwoven 4.FIG.13is a partial cross-section view of nonwoven 3.

The 35 gsm carded air-through nonwoven was put into a mechanical embossing-aperturing process illustrated inFIG.6comprising a pair of rolls having a configuration similar to one inFIG.7to produce Nonwoven 3. In the pair of rolls, a protrusion508in a first roll504and a groove514in the second roll506to be engaged with each other had a configuration illustrated inFIG.8C. That is, a first sidewall of the protrusion508was parallel to a first sidewall of the groove514facing the first sidewall of the protrusion508, and a second sidewall of the protrusion508was parallel to a second sidewall of the groove514facing the second sidewall of the protrusion508, and the side gap between the first sidewall of the protrusion508and the first sidewall of the groove514and the side gap between the second sidewall of the protrusion508and the second sidewall of the groove514are substantially identical. As a result, protruded area2in Nonwoven 3 was formed upon homogenous heat-compression, and it did not have a second area having a light reflectance different from a first area of the protruded area, referring toFIGS.11-13.

Nonwoven 4

Nonwoven 4 having features shown inFIGS.14-16was produced using the 35 gsm carded air-through nonwoven. The 35 gsm carded air-through nonwoven was put into a mechanical embossing-aperturing process the same as one to produce Nonwoven 3 above. A heat-fused area4in a recess8was formed using a heated meshed metal on Nonwoven 4.FIG.14is a plan view of Nonwoven 4, andFIG.15is a magnified plan view of part of Nonwoven 4.FIG.16is a partial cross-section view of nonwoven 4. Referring toFIGS.14-16, Nonwoven 4 has the same nonwoven configuration as Nonwoven 3 except that recess8has a heat-fused area, a third area4.

Example 2. Physical Properties of Nonwovens

Light reflectances, and areas and the maximum feret diameter of the second areas in Nonwovens 1 and 2 were measured according to Light Reflectance Test. Thicknesses of Nonwovens 1 and 2 were measured according to Thickness Test disclosed herein. All results are indicated in Table 1 below.

TABLE 1Nonwoven 1Nonwoven 2Thickness (μm)First area709.1648.4Second area50.457.7Third area340.5314.9Area of the second area (mm2)3.82.2Maximum feret diameter of the10.25.3second area* (mm)Light reflectanceFirst area98.899.9Second area112.2108.8Third area98.596.8Maximum feret diameter of the second area*: Length of the second area*

Example 3. Evaluation of Nonwoven Softness

Nonwovens 1-3 prepared in Example 1 were tested for nonwoven softness with 5 trained panels using a degree of difference (“DoD”) test between two test samples. The difference is scaled by 5 scores, i.e. 1-5 as below.

Score 1: No difference

Score 2: Slight difference, which can be told by well-trained softness panel, but cannot be told by consumers

Score 3: Noticeable difference

Score 4: Significant difference

Score 5: Outside normal range

TABLE 2Softness DoD scoreTest LegTest nonwovenScoreLeg 1Nonwoven 1 over Nonwoven 31Leg 2Nonwoven 2 over Nonwoven 32

Example 4. Evaluation of Three Dimensional Visibility

Nonwovens 2,3 and 4 prepared in Example 1 were tested for three dimensional impression of patterns in each nonwoven with 15 panels. First, 3 nonwoven samples of Nonwoven 2 and Nonwoven 3 were shown to each panel in a given sequence indicated in Table 3 below. When a panel correctly picked up the correct different sample among three samples, and commented pattern visibility, the result was recorded as positive. All results are indicated in Table 3 below.

Otherwise, the result was recorded as negative. Then, the same test was conducted using samples of Nonwoven 2 and Nonwoven 4 where 3 nonwoven samples of Nonwoven 2 and Nonwoven 4 were shown to each panel in a given sequence indicated in Table 4 below. All results are indicated in Table 4 below.

TABLE 3Picked-upPanelSampleas a differ-No.sequenceent oneCommentsResult1A*AB*BB looks much flatter than APositive2ABABB looks much flatter than APositive3ABBAA is a 3D material, but BPositivelooks like a 2D flat material4BAABB looks much flatter than APositive5BABAA looks more 3D than BPositive6BBAAB looks much flatter than APositive7AABBA looks more 3D than BPositive8ABABB looks much flatter than APositive9ABBAB looks much flatter than APositive10BAABB looks much flatter than APositive11BABAB looks much flatter than APositive12BBAAB looks much flatter than APositive13AABBA looks more 3-D than BPositive14ABABB looks much flatter than APositive15ABBAB looks much flatter than APositiveA*: Nonwoven 2B*: Nonwoven 3

TABLE 4Picked-upPanelSampleas a differ-No.consequenceent oneCommentsResult1A*AC*CC looks like a flatPositivematerial with lines,but not 3D material2ACACC looks like a flatPositivematerial with lines,but not 3D material3ACCN/ACannot tell the differenceNegative4CAACC looks like a flatPositivematerial with lines,but not 3D material5CACAA looks more 3D than CPositive6CCAAC looks like a flatPositivematerial with lines,but not 3D material7AACCC looks like a flatPositivematerial with lines,but not 3D material8ACACC looks like a flatPositivematerial with lines,but not 3D material9ACCAA looks more 3D than CPositive10CAACC looks like a flatPositivematerial with lines,but not 3D material11CACAC looks like a flatPositivematerial with lines,but not 3D material12CCAN/ACannot tell the differenceNegative13AACCC looks like a flatPositivematerial with lines,but not 3D material14ACACC looks like a flatPositivematerial with lines,but not 3D material15ACCAA looks more 3D than CPositiveA*: Nonwoven 2C*: Nonwoven 4

In most of tested legs with 15 panel, Nonwoven 2 was evaluated to have distinctively better pattern impression than Nonwoven 3 and Nonwoven 4.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”

Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present disclosure have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.