Articles Comprising Impregnated Thermoplastic Members And Method Of Manufacturing The Articles

Abstract

An article, including disposable articles and durable articles, includes one or more shaped thermoplastic members, which can be at least partially impregnated into one or more fibrous substrates forming a composite material of the article having regions of breathability, elasticity, and/or stiffening to provide desired functions of the article. The shaped thermoplastic members have a profiled thickness and/or basis weight providing variation in material properties. A percent variation of the profiled thickness of the thermoplastic member can vary from about 5% to about 95%. A process for manufacturing the composite material of the present invention is also disclosed.

1 . An absorbent article comprising:
 a topsheet;   a backsheet;   a fastening system comprising a thermoplastic member, wherein the thermoplastic member is tapered, and wherein the thermoplastic member is formed onto the absorbent article by one or more of the group consisting of printing, spraying, and coating.   
     
     
         2 . The absorbent article of  claim 1 , wherein the percent variation along at least one of an x, y, or z planes of the thermoplastic member varies from about 20% to about 80%. 
     
     
         3 . The absorbent article of  claim 1 , wherein the fastening system further comprises hooks and loops. 
     
     
         4 . The absorbent article of  claim 2 , wherein the fastening system comprises a slot and a tab. 
     
     
         5 . The absorbent article of  claim 4 , wherein the tab is formed in part by the thermoplastic member. 
     
     
         6 . The absorbent article of  claim 1 , wherein the thermoplastic member has a shape selected from the group consisting of an area having a rectilinear outline, a curvilinear outline, a triangle, a square, a trapezoid, a parallelogram, a polygon, a circle, an ellipse, and any combination thereof. 
     
     
         7 . The absorbent article of  claim 1 , wherein the thermoplastic member has at least one void defined by a shape selected from the group consisting of an area having a rectilinear outline, a curvilinear outline, a triangle, a square, a trapezoid, a parallelogram, a polygon, a circle, an ellipse, and any combination thereof. 
     
     
         8 . The absorbent article of  claim 1 , wherein the thermoplastic member comprises a material selected from the group consisting of a thermoplastic polymer, a thermoplastic member, a superabsorbent polymer, a polyolefin, a polyester, a polyamide, a polyurethane, a hot melt adhesive, and any mixture or combination thereof. 
     
     
         9 . The article of  claim 1 , wherein the absorbent article is selected from the group consisting of baby diapers, adult incontinence articles, feminine hygiene articles, and baby swim diapers. 
     
     
         10 . The absorbent article of  claim 1 , further comprising a second thermoplastic member in a waist area. 
     
     
         11 . The absorbent article of  claim 10 , wherein the second thermoplastic member is tapered and at least partially impregnated into a fibrous substrate. 
     
     
         12 . The absorbent article of  claim 11 , wherein there is a percent variation along at least one of an x, y, or z planes of the second thermoplastic member varies from about 20% to about 80%. 
     
     
         13 . An absorbent article comprising:
 a topsheet;   a backsheet;   a waist area comprising a thermoplastic member, wherein the thermoplastic member is tapered, and wherein the thermoplastic member that is at least partially impregnated into a fibrous substrate, such that a composite material is formed, and wherein the thermoplastic member is formed onto the absorbent article by one or more of the group consisting of printing, spraying, and coating.   
     
     
         14 . The absorbent article of  claim 13 , wherein there is a percent variation along at least one of an x, y, or z planes of the thermoplastic member varies from about 20% to about 80%. 
     
     
         15 . The absorbent article of  claim 13 , wherein the composite material comprises a stiffening region of the article having a modulus of elasticity from about 350 MPa to about 8000 MPa. 
     
     
         16 . The absorbent article of  claim 13 , wherein the composite material comprises a stiffening region having a tensile strength from about 25 MPa to about 6000 MPa. 
     
     
         17 . The article of  claim 13 , wherein the composite material forms an elastic region of the absorbent article having an elastic force at 200% elongation from about 50 grams/25.4 mm width to about 1000 grams/25.4 mm width. 
     
     
         18 . The absorbent article of  claim 13 , wherein the thermoplastic member has a shape selected from the group consisting of an area having a rectilinear outline, a curvilinear outline, a triangle, a square, a trapezoid, a parallelogram, a polygon, a circle, an ellipse, and any combination thereof. 
     
     
         19 . The absorbent article of  claim 13 , wherein the thermoplastic member has at least one void defined by a shape selected from the group consisting of an area having a rectilinear outline, a curvilinear outline, a triangle, a square, a trapezoid, a parallelogram, a polygon, a circle, an ellipse, and any combination thereof. 
     
     
         20 . The absorbent article of  claim 13 , wherein the thermoplastic member comprises a material selected from the group consisting of a thermoplastic polymer, a thermoplastic member, a superabsorbent polymer, a polyolefin, a polyester, a polyamide, a polyurethane, a hot melt adhesive, and any mixture or combination thereof. 
     
     
         21 . The absorbent article of  claim 13 , wherein the fibrous substrate is selected from the group consisting of a polymeric material, a natural material, a woven fabric, a non-woven fabric, a knit fabric, cellulose material, and any combination thereof. 
     
     
         22 . The absorbent article of  claim 13 , wherein the absorbent article is selected from the group consisting of baby diapers, adult incontinence articles, feminine hygiene articles, and baby swim diapers. 
     
     
         23 . The absorbent article of  claim 13 , wherein the waist area comprises a plurality of thermoplastic members, and wherein a back waist area within the waist area comprises at least one of the plurality of thermoplastic members that has a greater thickness than at least one other thermoplastic member of the plurality of thermoplastic members. 
     
     
         24 . The absorbent article of  claim 23 , wherein the waist area comprises a plurality of thermoplastic members, and wherein a back waist area within the waist area comprises at least one of the plurality of thermoplastic members that has a greater width than at least one other thermoplastic member of the plurality of thermoplastic members. 
     
     
         25 . The absorbent article of  claim 13 , wherein the composite material forms a breathable region of the article having a moisture vapor transmission rate of about 2,000 grams per m 2  per 24 hours to about 10,000 grams per m 2  per 24 hours (MVTR). 
     
     
         26 . The absorbent article of  claim 13 , wherein the composite material forms a breathable and liquid impermeable region of the article having a hydrostatic head from about 50 mm of water to about 700 mm of water. 
     
     
         27 . The absorbent article of  claim 13 , wherein the composite material forms a breathable and liquid impermeable region of the article having a dynamic fluid transmission value from about 0 grams/m 2  to about 5 grams/m 2  at an impact energy of 1000 Joules/m 2 . 
     
     
         28 . The absorbent article of  claim 1 , wherein the thermoplastic member is formed onto the absorbent article by one or more of the group consisting of ink jet printing, screen-printing, intaglio printing, flexographic printing, and rotogravure printing. 
     
     
         29 . The absorbent article of  claim 13 , wherein the thermoplastic member is formed onto the absorbent article by one or more of the group consisting of ink jet printing, screen-printing, intaglio printing, flexographic printing, and rotogravure printing.