Printed web

(54) Title: IMPRESSA MANTA AND METHOD OF (57) Summary:

PRODUCTION (30) Unionist Priority: 23/02/2007 us 11 / 710,214,

02/23/2007 US 11 / 710,215, 02/23/2007 US 11 / 710,367 (73) Owner (s): The Procter & Gamble Company.

(72) Inventor (s): Atsushi Ueminami, David Christopher Oetjen,

Paul Thomas Weisman (74) Attorney (s): Vieira de Mello Advogados.

(86) International order: pct US2008054267 from

19/02/2008 (87) International Publication: wo 2008 / i03650de

28/08/2008

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1/34

PRINTED BLANKET AND PRODUCTION METHOD

FIELD OF THE INVENTION

This invention relates to blankets useful for upper layers of disposable absorbent products, and, more specifically, disposable absorbent products that have visible images on an upper layer thereof.

BACKGROUND OF THE INVENTION

Disposable absorbent items, such as disposable diapers, sanitary napkins, panties protectors, interlabial devices, incontinence devices, training pants (children's underwear with a special thick lining between the legs used in the toilet use training phase), tampons, and the like, are known in the art. Printing on or below the top surface of an absorbent article is known in the art. Impressions that create a sign that masks spots, for example, are known. In a disposable absorbent article currently available on the market, such as the ALWAYS® sanitary napkins, a colored sign is printed on a layer underlying the upper layer, which is visible through the upper layer. By printing on a layer below the top layer, the colored signal can be seen through the top layer to provide a perception of depth within the absorbent article. The depth perception of a printed color signal appears to be particularly effective when the printed color signal is used in an upper layer

2/34 three-dimensional film formed t, as used in the aforementioned ALWAYS® sanitary napkin.

It would be desirable to obtain the demonstrated advantages of printing a colored sign on a layer below the top layer of a disposable absorbent article which either (1) does not require an underlying layer, or (2) which allows the elimination of a layer of material , or (3) which uses less ink or other printed media to achieve an acceptable level of visual perception by a user.

SUMMARY OF THE INVENTION

A blanket that has a dye and / or composition printed on it provides a skin health benefit. The blanket can be a three-dimensional polymeric blanket, permeable to fluids or a nonwoven blanket. The blanket may comprise a pattern of protuberances or a pattern of interconnected elements, with the interconnected elements defining openings. The openings are defined in a first surface of the mat, in a first plane of the mat, and extend through portions of the inner wall to a second surface in a second plane of the mat. A dye or lotion composition can be deposited on at least a portion of the second surface of the blanket.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective view of a portion of a three-dimensional formed film suitable for use in the present invention.

3/34

Figure 2 is a perspective view of a three-dimensional formed film suitable for use in the present invention.

Figure 3 is a perspective view of a three-dimensional formed film suitable for use in the present invention.

Figure 4 is an enlarged perspective view of a portion of the three-dimensional formed film shown in Figure 3.

Figure 5 is a perspective view of a three-dimensional formed film of the present invention.

Figure 6 is a perspective view of a disposable absorbent article of the present invention.

Figure 7 is a schematic representation of a flexographic printing process of the present invention.

Figure 8 is a detail of the printing process shown in figure 7.

Figure 9 is a photomicrograph of a blanket of the present invention.

Figure 10 is a photomicrograph of a blanket of the present invention.

Figure 11 is a schematic cross section of a nonwoven blanket of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

A blanket, a method and an apparatus for producing a blanket are presented. The blanket can be used beneficially as a top layer, or other component, in a disposable absorbent article. The blanket can be a non-woven blanket or a film

4/34 polymeric, since both are known known in the art for use in upper layers of disposable absorbent articles. In one embodiment, the blanket can be a non-woven blanket that is deformed locally, as by embossing, to have a three-dimensionality outside the plane, that is, in the Z direction. The Z direction, for use in the present invention, has its common meaning as used in the technique of non-woven blankets and absorbent articles, and refers to the direction generally orthogonal to the XY plane of a generally flat and generally smooth blanket. Embossed relief or other deformation made on a generally flat and smooth non-woven blanket is considered to be extended in the Z direction. Deformations in the Z direction on a blanket can be macroscopic, that is, visible to the naked eye from a distance of about 30.5 cm (12 inches), and as such can effectively increase the volume of the blanket. The volume is an inverse measure of density, that is, volume per unit mass, and can be increased by increasing the effective thickness of the mat without increasing the base weight of the mat. The three-dimensional protrusions formed by the deformations can define openings, and can be uniform in a dimension of the Z direction (i.e., height), such that the distal ends of the protrusions can be considered as terminating on a common plane or surface, as described later in this document, in relation to the films formed. The mat may be a formed film, such as a three-dimensional polymeric mat, expanded macroscopically and permeable to fluids. The description below is in the context of a one-way modality

5/34 similar.

<td>in</td><td>panties,</td>

<td>THE</td><td>blanket 40</td>

<td>in</td><td>freaks</td>

formed film but it should be understood that, in principle, the blanket, the apparatus, and the methods presented can be adapted for a non-woven blanket formed three-dimensionally.

Figure 1 is an enlarged, partially segmented perspective illustration of a three-dimensional polymer blanket, macroscopically expanded and permeable to fluids from a prior art, generally formed according to US patent No. 4,342,314, granted to Radel et al. , on August 3, 1982. Blankets of this type have been found to be highly suitable for use as a top layer in absorbent articles, such as sanitary pads, panties protectors, interlabial devices, and fluid-permeable exhibits a plurality of macroscopic surface aberrations that can be openings, such as openings primary 41. The primary openings 41 are formed by a multiplicity of interconnected elements, such as fiber-like elements, for example, 42, 43, 44, 45 and 46, which are connected to each other in order to define a first continuous surface 50 of the blanket 40 Each fiber-like element has a base portion, for example, as the base portion 51, located on the plane 52 of the first surface 50. Each base portion has a side wall portion, for example, as the side wall portion 53, attached to each longitudinal edge thereof. The sidewall portions generally extend towards a second discontinuous surface 55 of the blanket 40. The sidewall portions in

6/34 intersections are connected to each other via the first and second surfaces of the web, and end substantially simultaneously, with respect to each other, on the plane 56 of the second surface 55. The planes 52 and 56 can be substantially parallel and separated by a distance designated here as thickness or H gauge. In some embodiments, the base portion 51 may have surface aberrations 58, according to US patent No. 4,463,045, issued to Ahr et al., On July 31, 1984.

For use in the present invention, the term macroscopically expanded (a) refers to the structure of a mat formed from a mat or precursor film, for example a flat mat, which was made to adapt to the surface of a structure of three-dimensional formation, so that both sides, or surfaces, of the precursor mat are permanently altered due to its at least partial conformity with the three-dimensional pattern of the formation structure. The three-dimensional structure results in a first surface (for example, the first surface

50) and a second surface (for example, the second surface 55) that are separated at a predetermined distance, the predetermined distance being at least twice, three times, five times, or ten times the thickness of the precursor mat or film . These macroscopically expanded blankets are typically forced to adapt to the surface of the formation structure by means of embossing (embossing, that is, when the formation structure exhibits a pattern composed mainly of male-like projections), by means of in

7/34 reverse embossing (engraving in low relief, that is, when the formation structure exhibits a pattern composed mainly of depressions or openings of the female type), or through a combination of both techniques.

For use in the present invention, the term macroscopic refers to structural features or elements that are readily visible and clearly discernible to a human with 20/20 vision, when the perpendicular distance between the observer's eye and the blanket is about 3 0.5 cm (12 inches). Conversely, the term microscopic is used to refer to structural features or elements that are not readily visible and clearly discernible to a human with 20/20 vision, when the perpendicular distance between the observer's eye and the plane of the blanket is about 30.5 cm (12 inches). In general, for use in the present invention, the primary openings of a blanket, shown in the present invention, are macroscopic, and superficial aberrations, such as hair-like fibrils as shown below, in more detail, are considered microscopic.

The term plane (o), for use in the present invention, refers to the general condition of a blanket or precursor film, when seen with the naked eye on a macroscopic scale, before the permanent deformation of the blanket in a three-dimensional formed film. In this context, films extruded before post-extrusion processing and films that do not exhibit a significant degree of macroscopic three-dimensionality

8/34 permanent, for example, deformation outside the film plane, would be generically described as plans.

For use in the present invention, the term polymeric blanket refers to blankets formed substantially complete of polymeric material, such as polymeric and non-woven films. The term polymeric film refers to polymeric film blankets, including blankets made from polyethylene or polypropylene and commonly used in upper and lower layers of disposable absorbent articles. Polymeric films can be produced from means well known in the art, including extrusion, molding, blowing, and laminating methods, such as coextrusion. The term non-woven or non-woven blanket refers to non-woven polymeric blankets made from polymeric fibers, such as polyethylene, prolylene, PET, and combinations and blends, including bicomponent fibers, split fibers, and textile fibers . Nonwoven webs can be produced by means well known in the art, including melt blown production, hydroentanglement, carding, air deposition, continuous spinning, and the like.

For use in the present invention, the term interconnected elements refers to some or all of the elements of a blanket, for example, blanket 40 in Figure 1, portions of which serve to define the primary openings by a continuous network. As can be understood from the description of figure 1 and the description of the present invention presented here, the interconnected elements, for example, the fiber-like elements 42, 43, 44, 45 and 46, are

9/34 structurally continuous, with the contiguous interconnected elements mixing together in mutually contiguous transition portions. With reference to figure 1, the individual interconnected elements can best be described as those portions of the mat arranged between any two adjacent primary openings, which originate on the first surface and extend into the second surface. On the first surface of the mat, the interconnected elements collectively form a continuous network, or pattern, that defines the primary openings, and on the second surface of the mat, the interconnected side walls of the interconnected elements collectively form a discontinuous pattern of secondary openings. .

In a macroscopically expanded three-dimensional blanket, the interconnected elements can be described as channel-like. The two-dimensional cross-section of the interconnected elements can also be described as in a U-shape, as in Radel's patent 314, mentioned above, or in a concave shape upwards, as presented in US patent No. 5,514,105, granted on May 7 from 1996 to Goodman, Jr., et al. The term in a concave shape upwards, for use in the present invention, and as shown in figure 1, describes the channel-like shape orientation of the interconnected elements, in relation to the surfaces of the mat, with a base portion 51 usually on the first surface 50, and the legs, for example, the side wall portions 53, of the channel extending from the base portion 51 and towards the second surface 55,

10/34 the channel opening being located substantially on the second surface 55. In general, for a plane cutting the blanket, for example blanket 40, in orientation orthogonal to the plane, for example plane 52, of the first surface 50 and in intersection with any two adjacent primary openings, for example openings 41, the section cross section resulting from an interconnected element disposed there will exhibit a generally upward concave shape, which can be substantially U-shaped.

0 Continuous term, when used in the present invention to describe the first surface of a macroscopically expanded three-dimensional film web, refers to the uninterrupted characteristic of the first surface, generally in the plane of the first surface. Therefore, any point on the first surface can be reached from any other point on the first surface, without substantially leaving said first surface. On the other hand, as used in the present invention, the term discontinuous, when used to describe the second surface of a film sheet formed in three dimensions, refers to the broken characteristic of the second surface, generally in the plane of the second surface. Therefore, any point on the second surface cannot necessarily be reached from any other point on the second surface, without substantially leaving the second surface in the plane of said second surface.

Figure 2 shows an enlarged, partially segmented perspective illustration of a portion of a

11/34 polymeric blanket 110 provided with micro-openings the prior art, formed generally according to US patent No. 4,629,643, granted to Curro et al. The surface aberrations 120 with micro-openings can be formed by a hydroforming process, where a jet of liquid at high pressure is used to force the mat, to adapt it to a three-dimensional support element. As shown, ruptures that substantially coincide with the maximum amplitude of each surface aberration 120 provided with micro-openings result in the formation of a volcano-shaped opening 125 that has relatively thin irregularly shaped petals 126 around its periphery. The relatively thin petal-like edges 128 of the opening of such a blanket provide an enlarged impression of softness on a user's skin when compared, for example, to the Ahr '045 blanket. It is believed that this impression of softness is due to the relative lack of resistance to compression and shear supported by surface aberrations with volcano-shaped openings. For blankets of the type shown in figure 2, which have both macro-openings (as shown in the blanket in figure 1) and micro-openings that extend from the first surface 50, the H gauge is the dimension of plane 56 from second surface 55 to a plane of a surface corresponding generally to the petal-shaped edges 128 of the volcano-shaped openings 125.

Figure 3 is an enlarged, partially segmented perspective illustration of a macroscopically expanded three-dimensional polymer blanket 80 and permeable to

12/34 fluids, as presented in US application No. 10 / 324,366, filed December 20, 2002, and entitled Polymeric Web Exhibiting a Soft and Silky Tactile Impression. The geometric configuration of the macroscopic superficial aberrations, for example, the primary openings 71, of the polymeric blanket can be generically similar to that of the blanket 40, illustrated in figure 1. The primary openings 71 can here be called openings or macro-openings, and refer to openings in the mat that allow fluid communication between a first surface 90 of the mat 80 and a second surface 85 of the mat 80. The primary openings 71 of the mat shown in figure 3 are defined in plane 102 of the first surface 90 by a continuous network of interconnected elements, for example, elements 91, 92, 93, 94 and 95, interconnected to each other. The primary openings 71, as designed in the plane of the first surface 90, can be shaped like polygons, for example, squares, hexagons, etc., in an ordered or random pattern. In a preferred embodiment, the primary openings 71 have the modified oval shape and, in one embodiment, the primary openings 71 have the general shape of a teardrop. The polymer blanket 80 exhibits a plurality of surface aberrations 220, in the form of hair-like fibrils 225, as described more fully below. For blankets of the type shown in Figure 3, which have both macro-openings 71 and hair-like fibrils 225 extending from the first surface 90, gauge H is the dimension of plane 106 of second surface 85 to a plane of a corresponding surface, generally, at

13/34 distal ends 226 of hair-like fibrils

225.

In a three-dimensional polymeric blanket 80 provided with micro-openings, each interconnected element comprises a base portion, for example, the base portion 81, located generally on the 102 plane, and each base portion has side wall portions, for example, the side portions side wall 83 extending from each longitudinal edge thereof. The side wall portions 83 extend generally towards the second surface 85 of the blanket 80, and join the side walls of the contiguous interconnected elements, between the first and second surfaces, 90 and 85, respectively, ending substantially simultaneous to each other, defining the secondary openings, for example the secondary openings 72 in the plane 106 of the second surface 85.

Figure 4 is a partial enlarged view of the three-dimensional polymeric blanket 80 shown in figure 3. The three-dimensional polymeric blanket 80 comprises a polymer film 120, that is, the precursor film, which can be a single layer of extruded polymer, or a coextruded multilayer, or laminated film comprising two or more layers. As shown in figure 4, film 120 is a two-layer laminate comprising a first layer 101 and a second layer 103. Laminated materials can be coextruded, as is known in the art of producing laminated films, including films that comprise coating layers. Although it is currently preferred that, as shown in figure 4, the layers

14/34 polymeric, for example layers 101 and 103, end substantially simultaneously in the plane of the second surface 106, this is not currently believed to be essential. One or more layers may extend further towards the second surface than the others.

Figure 4 shows a plurality of superficial aberrations 220, in the form of hair-like fibrils 225. Hair-like fibrils are formed as protruding extensions of the polymeric blanket 80, generally on the first surface 90 thereof. The number, size and distribution of the hair-like fibrils 225 on the polymeric blanket 80 can be predetermined based on the sensation that one wishes to transmit to the skin. For applications such as the top layer in disposable absorbent articles, it is preferable that the hair-like fibrils 225 protrude only from the base portion 81, on the first surface 90 of the polymeric blanket 80, as shown in figures 3 and 4. Therefore, when blanket 80 is used as a top layer in a disposable absorbent article, the blanket can be oriented in such a way that the hair-like fibrils 225 come into contact with the skin for an impression of superior softness without, however, obstruct the flow of fluids through macro-openings 71. In addition, having the hair-like fibrils 225 with closed distal portions 226 results in reduced remoiling, that is, a reduction in the amounts of fluid being reintroduced to the surface of the layer

Upper 15/34, after first having passed through the upper layer to the underlying absorbent layers.

Figure 5 shows a mat of the present invention, the mat 140 of this modality being similar in all aspects to the mat of Fig. 1, except that it has a dye printed on the second surface 155 of the same, the dye of this modality being present in the form of ink tanks 160. Ink tanks 160 can be described as separate and spaced ink tanks. The dye can be any of the dyes suitable for deposition on a polymeric film, including water-based inks and dyes, solvent-based inks and dyes, UV-curable inks or dyes, inks, pigments, or liquid dyes as food dyes . The dye can produce a color that contrasts with the color of the blanket 140, and can be a primary color or a common color, such as red, green, blue, yellow, pink, purple, orange, or black. If blanket 140 is dark in color, the dye can have light colors like light gray, silver, white, or beige. The fluid permeable blanket 140 exhibits a plurality of macroscopic surface aberrations that can be openings, such as primary openings 141. Primary openings 141 are formed by a multiplicity of interconnected elements, such as fiber-like elements, for example, 142, 143, 144,

145 and 146, which are connected to each other in order to define a first continuous surface 150 of the blanket 140. Each fiber-like element has a base portion, for example, as the base portion 151, located on the plane 152 of the first surface 150. Each base portion has a portion

16/34 sidewall, for example, as the sidewall portion 153, connected to each longitudinal edge thereof. The sidewall portions generally extend towards a second discontinuous surface 155 of the blanket 140. The intersecting sidewall portions are connected to each other via the first and second surfaces of the blanket, and end substantially simultaneously, with respect to each other, in plane 156 of the second surface 155. The planes 152 and 156 can be substantially parallel and separated by a distance determined here as thickness or H gauge. In general, the H gauge of the blankets of the present invention useful as upper layers in disposable absorbent articles can be in the range of 0.1 to 2 mm, and may vary in increments of 0.01 mm between these values. H gauge can be from 0.40 to 0.60 mm. The H gauge can have an average value of about 0.44 mm. In some embodiments, the base portion 151 may have surface aberrations 158, according to US patent No. 4,463,045, granted to Ahr et al. , on July 31, 1984.

In some embodiments, the side wall portions 153 terminate substantially uniformly, such that the second surface 155 coincides substantially completely with the plane 156. However, in some embodiments, the side wall portions 153 may end in a substantially non-uniform manner, as in a relatively jagged pattern, with several portions having different height H dimensions. In such a modality, plan 156 can be considered as

17/34 being located at an average distance H, determined by the second surface 155. In each embodiment, the side wall portions are considered to extend to a second surface in a second plane of the blanket.

The ink deposits 160 are shown in the figure as being predominantly at the distal ends of the side walls 153, that is, substantially on the second surface 155. Due to the fact that the side walls can be relatively thin, including being thinned to the original thickness of the initial film mat material due to the production process, and due to the fact that the paint can be deposited in droplets that are larger than the thickness of the side wall, in some modalities, the ink deposits can extend a distance on the side wall 153 away from the distal end and still be considered to be substantially only on the second surface 155. Therefore, in one embodiment, the dyes in the form of ink deposits 160 on the second surface 155 may be on the edge of the film, or, primarily, on the edge of the film of the distal ends of the sidewall portions 153. In other embodiments, in addition to being on the edge of the film at the distal ends of the side wall portions 153, the paint may be on other parts of the side wall portions 153, including on the internal or external surfaces of the side wall portions 153.

An advantage of having dye deposited on at least a portion of the second surface of a film sheet formed in three dimensions, as a film illustrated in figure 5,

18/34 is the impression of depth that is created. When used as a top layer on an absorbent article, a blanket 345 that has a dye deposited on a plane below the top surface provides a good, deep visual impression that is pleasing to consumers. In addition, due to the fact that the dye is placed on a plane below the top surface, the dye is, in fact, as far away from the wearer's skin as possible, when the blanket is used as a top layer in an absorbent article. . This remote positioning can be beneficial for certain dyes, where it is undesirable that the dye is on or near the top surface of the top layer.

An advantage of the mat of the present invention, and the production methods described later in this document, is that the dye, or a combination of dyes, can be applied to the mat in areas other than the sidewall portions 153. For example, a dye it can be applied to be substantially limited to the second surface 155. Either the dye, or another dye that has a different color, can be applied between the first surface 150 and the second surface 153. If more than one color of dye is used, multiple color planes can be created to provide innovative visual effects for a user who looks at the blanket from the first side of the surface. When used in an upper layer of an absorbent article, various dyes, dye colors and positioning options can be combined to create innovative visual shapes, depth effects and color combinations. As an example, in one embodiment, a first dye can be

19/34 applied to the second surface of a central region of an upper layer of a sanitary napkin, and a second dye which has a different color can be applied to the second surface of one side or end region of the upper layer. In another embodiment, a first dye can be applied to the second surface of a central region of an upper layer of a sanitary pad in a swirl shape, and a second dye that has a different color can be applied to middle portions of the sidewall in the same region of the upper layer, and in the same swirl pattern, to provide an optical effect. Of course, any combination of dye, color, deposition location and deposition format can be contemplated, each with its own innovative visual effect.

The ink deposits 160 on the second surface 155 of the mat 140 can be applied by a printing process, such as gravure printing and flexographic printing, as described later in this document. Other printing processes that are known in the art can be used, each having several advantages and disadvantages. The advantage of printing through the flexographic printing process is that the configuration of the contact line, in the printing stage, can be adjusted and determined in such a way that only the second surface 155 of the blanket 140 comes into contact with the ink roller , in a highly controllable way. The result of this is that the ink deposits 160 can be precisely controlled, so that they are applied to the surface of the mat 140 spaced at a distance

20/34 predetermined from the first surface 150. As discussed above, when the blanket 140 is used as a top layer on a disposable absorbent article, ink deposits 160 on the second surface 155 can impart a perceived depth visible from the user side of the disposable absorbent article. When depth perception is achieved in this way, underlying layers, such as the upper secondary layers that have printed signs, can be eliminated without loss of color signaling capability. In addition, compared to printing a colored signal on an underlying layer, such as a secondary upper layer or a core layer, printing only on the second surface 155 of a formed film can significantly reduce the amount of ink used for a signal commercially viable visual.

The ink deposits 160 may be spaced closely together to form a substantially complete coverage of the second surface 155, or they may be spaced relatively far apart. The ink deposits 160 can be substantially limited to the ends of the side wall portions 153, or the ink deposit 160 can extend a substantial distance from the side wall portion 153 to the direction of the first surface 150. In one embodiment, ink deposits 160 are resistant to fading so that they do not dissolve, degrade, or spoil when offended by water, urine, or menstruation. In another modality, deposits of

21/34 ink 160 can be soluble in at least water, urine, or menstruation, in such a way that, under the action of liquid offensives, the printed color changes or disappears. Such a color change may indicate humidity, fluid volume, fluid position, and / or fluid type.

In one embodiment, ink deposits 160 can be printed to produce a graphic image visible from the side facing the user's body of a disposable absorbent article. For example, as shown in figure 6, the image may be similar to that shown in copending and co-patent US patent application No. 10 / 025,059, filed on December 19, 2001, entitled Absorbent Article, or in the copending and patent US application copertencente n ° 10 / 967,454, filed on October 18, 2004, entitled Absorbent Article.

Figure 6 provides a perspective view of the absorbent article 210. The absorbent article 210 of the present invention has an upper surface 222, a lower surface (not visible), and a periphery 212 comprising an upper layer 225 having a lower surface ( not shown) and a viewing surface 232 positioned opposite the bottom surface. The display surface 232 faces upwards towards the upper surface 222 of the absorbent article 210. The absorbent article 210 further comprises a lower layer 223 which has a surface facing the garment (not shown) and a surface facing the user positioned opposite the surface facing the garment, the lower layer 223 being joined to the layer

22/34 higher 225, as is common and known in the art. The absorbent article 210 also comprises an absorbent core 220 having a top surface 221 and a bottom surface (not shown) which is positioned opposite the top surface 221. The absorbent core 220 is positioned between the top layer 225 and the bottom layer 223, as is common and known in the art.

Ink deposits 160 can make a graph visible from the viewing surface

232, such a graphic 240 being shown in figure 6. In the embodiment shown in figure 6, the absorbent article 210 has at least two portions, that is, a portion comprising a graphic 240 and a portion 250 not comprising a graphic 240. A the graphic portion 240 and the non-graphic portion 250 can be viewed from the viewing surface 232 of the upper layer 225. The graphic 240 can have at least two shades, a first shade 242 and a second shade 244. In one embodiment, as shown in figure 6, a first hue 242 can be positioned substantially within the second hue 244. The second hue 244 may be different, both in brightness, darkness, and / or color, when compared to the first hue 242. These multi-shades can operate to create an additional perception of depth within the absorbent article, by a user looking at the viewing surface 22 of the upper layer 225.

While the graph shown in figure 6 is similar to the graph shown in US patent application No. 10 / 025,059 above, in the present invention, the format, size,

23/34 !

tin.gimen.to, position and intensity of graphic 240 can vary between shapes limited only by the size of the substrate and the printing techniques employed. For example, through the use of letter pressing, lithographic, silkscreen, flexographic or gravure printing techniques, virtually any graphic with any color or color combination can be placed on the top layer 225. In addition, by adjusting the processing variables such as the contact line between the cylinders in a flexographic process, the amount of ink and the position of the ink can vary to generate various impressions of color intensity, brightness / contrast, hue, saturation, and depth perception.

In one embodiment, the graphic 240 or another printed image can be given to a mat, such as the top layer 225, through a flexographic printing process, as shown schematically in figure 7. The flexographic printing process 300 can use any known flexographic printing apparatus and equipment, including processing means known in the art. As shown, the ink 305 is supplied by a chamber 310 which comprises a scraper blade, as is known in the art, and which is in operational relationship with a dispensing cylinder 320, to which the ink of the chamber

310 is transferred in a uniform manner, as the distribution cylinder 320 rotates in the indicated direction. The distribution cylinder 320 relates operationally to a lamination cylinder 330, such that in the transfer contact line 340 the ink is transferred from the

24/34 dispensing cylinder 320 for laminating cylinder 330. The laminating cylinder 330 receives the ink from the distribution cylinder 320 in a pattern corresponding to the desired pattern to be printed on a substrate 345. The substrate 345 on which the pattern will be printed, such as a blanket for a top layer of a disposable absorbent article, such as the sanitary napkin of figure 6, is fed to the central print drum 340 (in any conventional manner, not shown), which is rotating in the direction shown in figure 7.

As substrate 345 enters the print contact line 335 formed by the operational relationship of the surfaces of the laminating roller 330 and the central print drum 340, the ink 305 on the surface of the laminating roller 330 comes into contact with the substrate 345 and is transferred to substrate 345. Sometimes called ink printing, the ink transfer pattern corresponds to the graphic 240 which is then visible on the printed mat 350 and will eventually be visible from the viewing surface 232 of the top layer 225 of an absorbent article.

Alternatives can be implemented to the described flexographic printing process. For example, a plurality of print contact lines 335 can be arranged, each with its corresponding ink supply and lamination distribution cylinders, such that multiple patterns and graphics in multiple colors and color intensities can be provided. to the substrate 345. In one embodiment, two of these 335 print contact lines can be used, each contact line releasing

25/34 a color in a registered pattern, to create a graphic image of two colors on the substrate 345, such an image can then be registered so as to be properly arranged on the viewing surface 232 of the upper layer 225 of an article pad. In some embodiments, when multiple print operations are performed, it may be necessary for the ink in one print operation to be sufficiently dry before the next print operation. Therefore, in one mode, between printing operations, there may be drying means positioned in an operational manner, such as infrared heating, UV light curing, forced air circulation drying, and the like, as is known in the art.

There are many advantages of printing images on three-dimensionally formed film webs, by means of the present invention. For example, as shown in figure 8, a mat, like the mat 40 shown in figure 1, can be printed in a flexographic printing process, with the first surface 50 facing towards or on the central print drum 340, and with the second surface 55 outwardly relative to the central print drum 340. The gap G between the laminating cylinder 330 and the central printing drum 340 can be adjusted in such a way that the ink is transferred only to the second surface 55 of the mat 40, which, in this embodiment, is the substrate 345 that is printed to be the printed mat 350. Once printed, printed mat 350 is a mat 140 of the present invention, as shown in figure 5. The ink was transferred through the flexographic process to be deposited only in the second

26/34 surface 155 and, depending on the gap G, in portions of the side walls 153.

The span G can be adjusted depending on the H gauge of the substrate 345 of three-dimensional formed film webs.

In one embodiment, the span G can be substantially equal to the gauge H, such that the paint is deposited only at the ends of the side wall portions 153 of the second surface 155. In another embodiment, the span G may be smaller than the gauge H, such that portions of the sidewall 153 are compressed through the print contact line 335, resulting in the deposition of ink on a portion of the sidewalls 153. Figure 9 is a photomicrograph of a section about 3 mm long (horizontally in Figure 9) of the second surface 155 of a mat 140 of the present invention showing deposits of paint 160 at the ends of the side wall portions 153, substantially at the second surface 155. Figure 9 shows the underside of a blanket similar to that shown in Figure 5, the term underside being used to denote the side of the blanket opposite the first surface 150, and including the second surface 155. During use, any side can be the lower side, therefore, the term is used here simply to denote the printed side, which is the lower side, as shown in figure 5, for example.

As configured in figure 9, the blanket 140 is folded to better show the cone-shaped structure formed by the side wall portions 153 at the top of the figure. As shown, ink 305 is printed in a dot pattern with close spacing, at the distal ends of the

27/34 side wall 153, by a flexographic printing process, as described above, with reference to figure 7. For the substrate of three-dimensional blankets of formed film 345 printed and represented in figure 9 as the blanket 140, the ink is a water-based ink available as GCOFW7835747 RD 11, from Sun Chemical, applied to a three-dimensional formed film produced by Tredegar Film Products, at the Haung Pu mill in Guangzhou, GD, China, having an H gauge of 0.44 mm (when measured under a load of 14.7 g / cm²), in a PROGLIDE® flexographic printing process, made by Mark Andy / Comco, Inc. 910 Lila Ave., Milford, Ohio, USA, where the G gap was adjusted to be about 0.254 mm (0.01).

In another embodiment, the gap G can be adjusted in such a way that in the printing contact line 335, the substrate 345 of three-dimensional webs of formed film is significantly compressed, so that the ink is deposited on practically all surfaces of the printed mat 140, except the first surface, such as the first surface 50 of the mat shown in figure 1. Figure 10 is a photomicrograph of a section about 3 mm long (horizontally in Figure 10) of the second surface 155 of a mat of the present invention, which shows ink deposited on practically the entire bottom side of the mat 140, the term "side". bottom being used to denote the side of the mat opposite the first surface 150, and including the second surface 155. During use, either side can be the underside, so the term is used here simply to denote the printed side which is the

28/34 lower, as shown in figure 5, for example. As configured in figure 10, the blanket 140 is folded to better show the cone-shaped structure formed by the side wall portions 153 at the top of the figure. As shown in figure 10, the cone-shaped structures were deformed in some way by compaction during the printing process, and ink 305 is printed in a dot pattern with close spacing over virtually the entire underside of the mat, for a flexographic printing process, as described above, with reference to figure 7. For the printed three-dimensional film web substrate 345 printed and represented in figure 10, the ink is a solvent-based ink available as CROFS7711705 DPO-149, made by Sun Chemical, applied to a three-dimensional formed film, produced by Tredegar Film Products , at the Haung Pu mill in Guangzhou, GD, China, having an H gauge of 0.44 mm (when measured under a load of 14.7 g / cm²) in a PROGLIDE® flexographic printing process, made by Mark Andy / Comco, Inc. 910 Lila Ave., Milford, Ohio, USA, where the G gap has been adjusted to be about 0.0 mm (0.0).

In one embodiment, the mat of the present invention can be described as a three-dimensional fluid-permeable mat comprising a pattern of protuberances. As shown in figure 11, substrate 345 may comprise a nonwoven mat 350 made from known processes, including melt blown production, continuous spinning, carding, air deposition, and wet deposition (for example, paper), fibers can be

29/34 synthetic, bicomponent, cellulosic, nanofibers, microfibers, formed fibers, fibers treated with surfactant, and other types of fiber, as known in the art, and the blanket can have sufficient light transmittance so that the printed signal of a side can be seen through the blanket on the other side. The 360 ​​protrusions can be produced by means known in the art, including hot punch punch, hot punch aperture, embossing, hydroforming and vacuum forming. Two protrusions 360 are shown in the partial cross-sectional view of figure 11, one having a distal end closed and the other with a distal end provided with openings. The protrusions 360 may extend from portions of the inner wall to the distal ends 362, which collectively define a second discontinuous surface 355 in a background 356 of the mat. The dye 370, like an ink or pigment, can be deposited on at least a portion of the distal ends 362 of the protrusions 360, that is, on the second surface

355 the blanket. The protrusions 360 may include or define openings 365, the openings being defined in a first surface 354 of said blanket, in a first plane 352 of the blanket, and extending from portions of the inner wall to openings in substantially the entire second plane thereof . The distance H, which can be considered as the effective thickness of the three-dimensional mat 350 between the first plane 352 and the second plane 356, can be twice the average thickness of the non-woven mat used as a base, or three times, or four times, or at least

30/34 about five times. Such a blanket can be beneficially used in sanitary napkins, due to the fact that an upper layer using such a blanket does not require an underlying layer to provide a colored signal visible to a user from the surface of the upper layer. In addition, by printing on a non-woven blanket used as an upper layer, the manufacturer can eliminate a layer of material, such as a secondary upper layer, if the secondary upper layer was otherwise used as the printing surface where printed a colored sign visible to the user from the top layer surface. In addition, the printing of a colored sign on the non-woven blanket used as a top layer, as described in the present invention, uses less ink or other printed medium to achieve an acceptable level of visual perception for the user. Through ink printing, for example, only on the distal portions, that is, on the tips of the protuberances of the second surface, a relatively smaller amount of ink may be sufficient to provide a commercially acceptable visual signal to a user of a disposable absorbent product.

In one embodiment, therefore, the blanket of the present invention can be described as a fluid-permeable three-dimensional polymeric blanket, the blanket comprising a pattern of interconnected elements, the interconnected elements defining openings, the openings being defined on a first surface of said blanket in a foreground of said blanket and extending from the portions

31/34 from the inner wall to a second surface in a second layer of the mat, and where the paint is deposited on at least a portion of the second surface of the mat. A blanket of this type, sometimes called a macroscopically expanded film, has a beneficial use in sanitary napkins, due to the fact that an upper layer using such a blanket does not require an underlying layer to provide a colored signal visible to a user from the top layer surface. Additionally, by printing on a mat used as an upper layer, the manufacturer can eliminate a layer of material, such as a secondary upper layer, if the secondary upper layer was otherwise used as the printing surface where a colored sign was printed visible to a user from the top layer surface. In addition, the printing of a colored sign on the mat used as a top layer, as described in the present invention, uses less ink or other printed medium to achieve an acceptable level of visual perception for a user. Through ink printing, for example, only at the tips of the macroscopically expanded cones of the second surface, a relatively smaller amount of ink may be sufficient to provide a commercially acceptable visual signal to a user of a disposable absorbent product.

In another modality, lotions, surfactants, creams, and other compositions that provide health benefits to the skin can be applied to the second surface of a blanket, the above description being applied, for example.

32/34 example, to a lotion replaced by a dye such as an ink or pigment. In one embodiment, for example, a clear or petrolatum-dyed lotion can be applied through known methods, such as heating it sufficiently for application, by means of flexographic printing. Once deposited on the blanket, the heated petrolate composition can then be cooled to solidify in place, as in the side wall portions of the blanket. In this way, lotions and lotion compositions can be applied alone, or as the dye, or with a dye, or in combination with multiple dyes at multiple sites on the mat of the present invention, to provide skin health benefits. Lotion compositions, for example, can be applied to the second surface of a blanket used as an upper layer, such that, during use, due to body heat, wear movement, or fluid migration, the composition of lotion may come into contact with the user's skin.

In another embodiment, a laminate of formed film or nonwoven can be printed. In one embodiment, a non-woven blanket can be attached, either by adhesive or by heat-sealing, to a surface of a formed film, both before and after its formation in a fluid-permeable three-dimensional polymeric blanket. In this way, a formed film that has a smooth, fibrous surface can be obtained.

In another modality, blankets that have tufts formed in it, including laminates of films and nonwovens,

33/34 can be printed as shown in the present invention. In one embodiment, tufts can be formed by needle punching, or by rotating methods known as SELF (Structural Elastic Like Film), formation of openings by rotating knives, and the like, as shown in US orders copendants and assigned to the same applicant, serial number 11 / 156,020, filed on June 17, 2005, serial number 10 / 737,306, filed on December 16, 2003, and serial number 10 / 737,430, deposited on December 16, 2003. The method of the present invention can be used to deposit a lotion, dye, or other fluid material on the tips of the tufts. In one embodiment, the method of the present invention can be used to print inks or dyes only on the tips of the tufts of a blanket with non-woven or laminated tufts.

All documents cited in the detailed description of the invention are, in their relevant part, incorporated herein by way of reference. The citation of any document should not be interpreted as an admission that it represents prior art with respect to the present invention. To the extent that any meaning or definition of a term in this written document conflicts with any meaning or definition of the term in a document incorporated by reference, the meaning or definition assigned to the term in this written document shall prevail.

The dimensions and values ​​presented in the present invention should not be understood as being strictly limited to the exact numerical values ​​mentioned. Instead, except otherwise

34/34 specified, each of these dimensions is intended to mean both the mentioned value and a range of functionally equivalent values ​​around that value. For example, a dimension shown as 40 mm is intended to mean about 40 mm.

Although specific embodiments of the present invention have been illustrated and described, it should be obvious to those skilled in the art that various other changes and modifications can be made without departing from the character and scope of the invention. Therefore, it is intended to cover in the appended claims all such changes and modifications that fall within the scope of the present invention.

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