Absorbent articles having apertured, three-dimensional materials and methods for making same

Abstract

An absorbent article is provided. The absorbent article includes a nonwoven, liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent core disposed at least partially intermediate the topsheet and the backsheet. The absorbent article includes an apertured substrate having a layer of fibers and has a plurality of apertures defined in the layer of fibers. At least some of the apertures have a side wall having a portion disposed an angle in the range of about 55 degrees to about 90 degrees, according to the 2D X-Ray CT Scan Test herein.

What is claimed is: 
     
         1 . An absorbent article comprising:
 a liquid permeable topsheet;   a liquid impermeable backsheet; and   an absorbent core disposed at least partially between the topsheet and the backsheet;   wherein the absorbent article comprises an apertured substrate comprising:
 a layer of fibers; 
 a plurality of apertures defined in the layer of fibers; 
 a first surface extending in a first plane; and 
 a second surface extending in a second plane; 
 wherein at least some of the plurality of apertures have a first surface-facing opening area and a second surface-facing opening area, wherein the first surface-facing opening area extends in the first plane, wherein the second surface-facing opening area extends in the second plane, wherein the first plane is parallel to the second plane, and wherein the first surface-facing opening area is larger than the second surface-facing opening area; and 
 wherein the at least some of the plurality of apertures comprise a side wall, wherein at least a portion of the side wall has an angle in the range of about 55 degrees to about 90 degrees, according to the 2D X-Ray CT Scan Test. 
   
     
     
         2 . The absorbent article of  claim 1 , wherein the second surface-facing opening area of the at least some of the plurality of apertures is in the range of about 1.0 mm 2  to about 7.5 mm 2 , according to the 2D X-Ray CT Scan Test. 
     
     
         3 . The absorbent article of  claim 1 , wherein the first surface-facing opening area of the at least some of the plurality of apertures is in the range of about 2 mm 2  to about 12 mm 2 , according to the 2D X-Ray CT Scan Test. 
     
     
         4 . The absorbent article of  claim 1 , wherein the at least some of the plurality of apertures have a central major axis dimension and a central minor axis dimension, and wherein the central major axis dimension is greater than 1.5 mm, when measured at the second surface-facing opening area, according to the 2D X-Ray CT Scan Test. 
     
     
         5 . The absorbent article of  claim 4 , wherein a ratio of the central major axis dimension to the central minor axis dimension is at least 1.3, but less than 4, when measured at the garment-facing opening area, according to the 2D X-Ray CT Scan Test herein. 
     
     
         6 . The absorbent article of  claim 1 , wherein at least some of the fibers comprise bicomponent fibers comprising a core and a sheath. 
     
     
         7 . The absorbent article of  claim 6 , wherein the sheath comprises polyethylene, and wherein the core comprises polyethylene terephthalate. 
     
     
         8 . The absorbent article of  claim 1 , wherein the layer of fibers comprises carded fibers. 
     
     
         9 . The absorbent article of  claim 1 , wherein the at least some of the side walls of the apertures have a length in the range of about 0.2 mm to about 2.0 mm, according to the 2D X-Ray CT Scan Test herein. 
     
     
         10 . The absorbent article of  claim 1 , wherein the apertured substrate has a first spacing in a first direction between adjacent apertures of the plurality of apertures, as measured at the first surface; wherein the apertured substrate has a second spacing in a second direction between adjacent apertures of the plurality of apertures, as measured at the first surface; wherein the second direction is substantially perpendicular to the first direction; and wherein the second spacing is different than the first spacing. 
     
     
         11 . The absorbent article of  claim 10 , wherein the second spacing is between about 2.5 mm and about 8.5 mm. 
     
     
         12 . The absorbent article of  claim 10 , wherein a ratio of the first spacing to the second spacing is between about 0.34 and about 1.23. 
     
     
         13 . The absorbent article of  claim 12 , wherein the apertured substrate has an Effective Open Area is in the range of about 18% to about 25%. 
     
     
         14 . The absorbent article of  claim 1 , wherein the liquid permeable topsheet, the liquid impermeable backsheet, and the absorbent core form at least a portion of a central chassis, and wherein the apertured substrate forms at least a portion of a front belt and/or a back belt. 
     
     
         15 . The absorbent article of  claim 14 , wherein the front belt and/or the back belt further comprises an elastomeric material. 
     
     
         16 . The absorbent article of  claim 1 , wherein the apertured substrate forms a portion of the liquid permeable topsheet. 
     
     
         17 . The absorbent article of  claim 1 , wherein the apertured substrate comprises more than one layer. 
     
     
         18 . The absorbent article of  claim 1 , wherein the apertured substrate is joined to a second substrate, wherein the second substrate is devoid of apertures. 
     
     
         19 . An absorbent article comprising:
 a liquid permeable topsheet;   a liquid impermeable backsheet; and   an absorbent core disposed at least partially between the topsheet and the backsheet;   wherein the absorbent article comprises an apertured substrate comprising:
 a layer of fibers; 
 a plurality of apertures defined in the layer of fibers; 
 a first surface extending in a first plane; and 
 a second surface extending in a second plane; 
 wherein at least some of the plurality of apertures have a first surface-facing opening area and a second surface-facing opening area, wherein the first surface-facing opening area extends in the first plane, wherein the second surface-facing opening area extends in the second plane, wherein the first plane is parallel to the second plane, and wherein the first surface-facing opening area is larger than the second surface-facing opening area; 
 wherein the at least some of the plurality of apertures comprise a side wall, wherein at least a portion of the side wall has an angle in the range of about 55 degrees to about 90 degrees, according to the 2D X-Ray CT Scan Test; 
 wherein the first surface-facing opening area of the at least some of the plurality of apertures is in the range of about 2 mm 2  to about 12 mm 2 , according to the 2D X-Ray CT Scan Test; 
 wherein the second surface-facing opening area of the at least some of the plurality of apertures is in the range of about 1.0 mm 2  to about 7.5 mm 2 , according to the 2D X-Ray CT Scan Test; and 
 wherein the apertured substrate has a first spacing in a first direction between adjacent apertures of the plurality of apertures, as measured at the first surface; wherein the apertured substrate has a second spacing in a second direction between adjacent apertures of the plurality of apertures, as measured at the first surface; wherein the second direction is substantially perpendicular to the first direction; and wherein the second spacing is different than the first spacing. 
   
     
     
         20 . An absorbent article comprising:
 a liquid permeable topsheet;   a liquid impermeable backsheet; and   an absorbent core disposed at least partially between the topsheet and the backsheet;   wherein the absorbent article comprises an apertured substrate comprising:
 a layer of fibers; 
 a plurality of apertures defined in the layer of fibers; 
 a first surface extending in a first plane; and 
 a second surface extending in a second plane; 
 wherein at least some of the plurality of apertures have a first surface-facing opening area and a second surface-facing opening area, wherein the first surface-facing opening area extends in the first plane, wherein the second surface-facing opening area extends in the second plane, wherein the first plane is parallel to the second plane, and wherein the first surface-facing opening area is larger than the second surface-facing opening area; 
 wherein the at least some of the plurality of apertures comprise a side wall, wherein at least a portion of the side wall has an angle in the range of about 55 degrees to about 90 degrees, according to the 2D X-Ray CT Scan Test; 
 wherein the apertured substrate has a first spacing in a first direction between adjacent apertures of the plurality of apertures, as measured at the first surface; wherein the apertured substrate has a second spacing in a second direction between adjacent apertures of the plurality of apertures, as measured at the first surface; wherein the second direction is substantially perpendicular to the first direction; and wherein the second spacing is different than the first spacing; 
 wherein the liquid permeable topsheet, the liquid impermeable backsheet, and the absorbent core form at least a portion of a central chassis, and wherein the apertured substrate forms at least a portion of a front belt and/or a back belt; and 
 wherein the apertured substrate is joined to a second substrate, wherein the second substrate is devoid of apertures.