Absorbent articles having pockets and related methods therefor

• US 10,369,246 B2
• Filed: 09/30/2013
• Issued: 08/06/2019
• Est. Priority Date: 06/14/2013
• Status: Active Grant

• Current Assignee: Kpr U.S., LLC (Cardinal Health, Inc.)
• Original Assignee: KRP US LLC
• Inventors: Patel, Harish A., Gahan, Richard E., Narvekar, Vishal
• Primary Examiner(s): Kidwell, Michele M
• Application Number:
  US14/040,761
• Publication Number:
  US 20140371700A1
• Time in Patent Office: 2,136 Days
• Field of Search: 60438501, 604367
• CPC Class Codes: A61F 13/534 having an inhomogeneous composition through the thickness of the pad A61F13/538, A61F13/539 take precedence; homogeneous cores with tissue wrapping A61F13/53
• CPC Class Codes: A61F 13/535 inhomogeneous in the plane of the pad, e.g. core absorbent layers being of different sizes A61F13/5323, A61F13/537 take precedence
• CPC Class Codes: A61F 13/539 characterised by the connection of the absorbent layers with each other or with the outer layers
• CPC Class Codes: A61F 2013/530153 being long
• CPC Class Codes: A61F 2013/530562 being arranged in discontinuous pattern
• CPC Class Codes: A61L 15/20 containing organic materials
• CPC Class Codes: A61L 15/24 Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives thereof A61L15/225 takes precedence
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor

Abstract

The present disclosure provides articles having an absorbent core. The absorbent core has a plurality of segmented volumes possessing an absorbent material therein. Suitable articles which may be formed with this absorbent core include, for example, diapers such as infant diapers, juvenile diapers and training pants, feminine hygiene products such as menstrual pads, adult incontinence products such as adult briefs, protective underwear, pads and bladder control pads, pet training pads, and other disposable products utilized to absorb fluids.

Claims

1. An absorbent article comprising:

a fluid permeable inner layer;

an impermeable outer layer substantially coextensive with the fluid permeable inner layer and opposed to the fluid permeable inner layer;

an absorbent core comprising a network of filaments disposed between the permeable inner layer and the impermeable outer layer, the filaments defining a plurality of apertures extending through the network,

wherein the filaments of the network secured to the fluid permeable inner layer and the impermeable outer layer define a plurality of pockets in the absorbent core configured to contain a superabsorbent material within respective apertures in the network in the absorbent core and between the fluid permeable inner layer and the impermeable outer layer; and

the superabsorbent material contained within each pocket of the plurality of pockets.

2. The absorbent article of claim 1, wherein the absorbent core further comprises fluff pulp in at least one of the plurality of pockets.

3. The absorbent article of claim 1, wherein the network comprises a polymeric material having a melting point less than a melting point of a material comprising the permeable inner layer.

4. The absorbent article of claim 3, wherein the polymeric material comprises a polymer selected from the group consisting of polyethylene, polypropylene, polyester, and polyamide.

5. The absorbent article of claim 1, wherein the plurality of pockets is defined by the filaments of the network adhesively secured to the permeable inner layer and to the impermeable outer layer.

6. The absorbent article of claim 1, wherein each of the plurality of pockets is substantially about a same size.

7. The absorbent article of claim 1, wherein the superabsorbent material comprises starch-graft polymers and cross-linked polyacrylate polymers.

8. The absorbent article of claim 1, wherein the superabsorbent material is a polymer selected from the group consisting of polyacrylamide, polyethylene oxide, polyvinyl alcohol, polysuccinimide, and hydrolyzed polyacrylonitrile.

9. The absorbent article of claim 1, wherein the network of filaments comprises cotton with a thread count per square inch of in a range of from 2×

2 to 8×

8, wherein at least a portion of the filaments are secured to the permeable inner layer and to the impermeable outer layer with an adhesive.

10. The absorbent article of claim 1, wherein at least a portion of the pockets are sized to have at least one dimension in a range of from about 0.125 inch to about 1 inch.

11. The absorbent article of claim 1 having at least a portion of said plurality of pockets with a first area and at least a portion of said plurality of pockets with a second area, said first area greater than the second area, and wherein said at least a portion of said plurality of pockets with said first area disposed at a peripheral zone of the absorbent article.

12. The absorbent article of claim 1, wherein at least a portion of the filaments comprises an elastomeric material with a diameter in a range of from about 250 microns to about 500 microns.

13. The absorbent article of claim 1, wherein the article is selected from the group consisting of diapers and protective undergarments.

21. The absorbent article of claim 1, wherein the fluid permeable inner layer comprises a bicomponent fiber.

22. The absorbent article of claim 1, wherein the impermeable outer layer defines an outer surface of the absorbent article.

23. The absorbent article of claim 1, wherein the impermeable outer layer is secured to the fluid permeable inner layer along a peripheral region of the absorbent article.

14. A method of preparing an absorbent article having a permeable inner layer and an impermeable outer layer, the method comprising disposing superabsorbent material between a network of filaments and securing at least a portion of the network of filaments to at least one of the fluid permeable inner layer and the impermeable outer layer, the filaments defining a plurality of apertures extending through the network, wherein the filaments of the network, the fluid permeable inner layer, and the impermeable outer layer combine to define a plurality of pockets configured to contain the superabsorbent material within respective apertures in the network, and between the fluid permeable inner layer and the impermeable outer layer, wherein the superabsorbent material is contained within each pocket of the plurality of pockets.

15. The method of claim 14, wherein securing the at least a portion of the network of filaments comprises melting at least a portion of the filaments.

16. The method of claim 14, wherein securing the at least a portion of the network of filament defines an absorbent layer having a plurality of pockets and wherein the method further comprises disposing fluff pulp into at least a portion of the plurality of pockets.

17. The method of claim 14, wherein securing the at least a portion of the network of filaments comprises adhesively securing at least a portion of the network of filaments to the impermeable outer layer.

18. The method of claim 17, wherein adhesively securing the at least a portion of the network of filaments to the impermeable outer layer comprises applying, on at least one of the impermeable outer layer and the network of filaments, an adhesive comprising at least one hydrophilic polymer.

19. A protective undergarment comprising:

a top sheet;

a bottom sheet substantially coextensive with the top sheet and opposed to the top sheet;

an absorbent core comprising a network of filaments disposed between the top sheet and the bottom sheet, the filaments defining a plurality of apertures extending through the network,

wherein the filaments of the network-secured to the top sheet and the bottom sheet define a plurality of pockets in the absorbent core containing a superabsorbent material within respective apertures in the network in the absorbent core and between the top sheet and the bottom sheet; and

the superabsorbent material contained within each pocket of the plurality of pockets.

20. The protective undergarment of claim 19, wherein the plurality of pockets is defined by the filaments of the network adhesively secured to the top sheet and to the bottom sheet.

24. The protective undergarment of claim 19, wherein the bottom sheet defines an outer surface of the protective undergarment.

25. The protective undergarment of claim 19, wherein the bottom sheet is secured to the top sheet along a peripheral region of the protective undergarment.