Reticulated absorbent composite
First Claim
1. An absorbent composite comprising a core and a fibrous stratum, the core and stratum being integrally formed;
- wherein the stratum is coextensive with a surface of the core, wherein the core comprises a fibrous matrix and absorbent material, wherein the fibrous matrix defines voids and passages between voids distributed substantially throughout the matrix, wherein the absorbent material is located within some of the voids; and
wherein the absorbent material located within the voids is expandable into the voids.
2 Assignments
0 Petitions
Accused Products
Abstract
An absorbent composite having a reticulated core and a fibrous stratum is disclosed. The core and stratum are integrally formed, and the stratum is coextensive with a surface of the core. In one embodiment, the composite includes strata on opposing surfaces of the core. The core includes a fibrous matrix and absorbent material. The fibrous matrix defines voids and passages between the voids, which are distributed throughout the composite. Absorbent material is located within some of the voids. On wetting, absorbent material located in these voids is expandable into the void. Methods for forming the composite and absorbent articles that include the composite are also disclosed.
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Citations
114 Claims
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1. An absorbent composite comprising a core and a fibrous stratum, the core and stratum being integrally formed;
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wherein the stratum is coextensive with a surface of the core, wherein the core comprises a fibrous matrix and absorbent material, wherein the fibrous matrix defines voids and passages between voids distributed substantially throughout the matrix, wherein the absorbent material is located within some of the voids; and
wherein the absorbent material located within the voids is expandable into the voids. - View Dependent Claims (2, 3, 4, 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 101, 102)
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6. The composite of claim 6 wherein the polyester fibers are polyethylene terephthalate fibers.
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17. A wetlaid absorbent composite comprising a core and a fibrous stratum, the core and stratum being integrally formed;
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wherein the stratum is coextensive with a surface of the core, wherein the core comprises a fibrous matrix and absorbent material, wherein the fibrous matrix defines voids and passages between voids distributed substantially throughout the matrix, wherein the absorbent material is located within some of the voids; and
wherein the absorbent material located within the voids is expandable into the voids. - View Dependent Claims (18, 19, 20, 103, 104)
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21. A foam-formed absorbent composite comprising a core and a fibrous stratum, the core and stratum being integrally formed;
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wherein the stratum is coextensive with a surface of the core, wherein the core comprises a fibrous matrix and absorbent material, wherein the fibrous matrix defines voids and passages between voids distributed substantially throughout the matrix, wherein the absorbent material is located within some of the voids; and
wherein the absorbent material located within the voids is expandable into the voids. - View Dependent Claims (22, 23, 24, 105, 106)
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25. An absorbent composite comprising a core and first and second fibrous strata, the core and strata being integrally formed;
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wherein the core is intermediate the first and second strata;
wherein the first and second strata are coextensive with opposing surfaces of the core, wherein the core comprises a fibrous matrix and absorbent material, wherein the fibrous matrix defines voids and passages between voids distributed substantially throughout the matrix, wherein the absorbent material is located within some of the voids; and
wherein the absorbent material located within the voids is expandable into the voids. - View Dependent Claims (26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 107, 108)
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37. A wetlaid absorbent composite comprising a core and first and second fibrous strata, the core and strata being integrally formed;
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wherein the core is intermediate the first and second strata;
wherein the first and second strata are coextensive with opposing surfaces of the core, wherein the core comprises a fibrous matrix and absorbent material, wherein the fibrous matrix defines voids and passages between voids distributed substantially throughout the matrix, wherein the absorbent material is located within some of the voids; and
wherein the absorbent material located within the voids is expandable into the voids. - View Dependent Claims (109, 110)
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38. A foam-formed absorbent composite comprising a core and first and second fibrous strata, the core and strata being integrally formed;
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wherein the core is intermediate the first and second strata;
wherein the first and second strata are coextensive with opposing surfaces of the core, wherein the core comprises a fibrous matrix and absorbent material, wherein the fibrous matrix defines voids and passages between voids distributed substantially throughout the matrix, wherein the absorbent material is located within some of the voids; and
wherein the absorbent material located within the voids is expandable into the voids. - View Dependent Claims (111, 112)
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- 39. An absorbent composite comprising absorbent material in a fibrous matrix, wherein the composite has an edgewise ring crush value in the range from about 400 to about 1600 grams and a basis weight in the range from about 250 to about 650 gsm.
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44. An absorbent composite comprising absorbent material in a fibrous matrix,
wherein the absorbent material is present in the composite in an amount from about 40 to about 80 percent by weight based on the total weight of the composite; -
wherein the fibrous matrix comprises crosslinked cellulosic fibers and matrix fibers;
wherein the weight ratio of crosslinked fibers to matrix fibers is at least about 1;
1. - View Dependent Claims (45, 46)
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47. A method for forming an absorbent composite, comprising the steps of:
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combining resilient fibers, matrix fibers, and absorbent material in a dispersion medium to form a fibrous slurry;
depositing the fibrous slurry on a foraminous support;
withdrawing water from the deposited slurry to provide a wet composite having a fibrous stratum adjacent the support; and
drying the wet composite to form an absorbent composite having a core and a fibrous stratum, the core and stratum being integrally formed, wherein the stratum is coextensive with a surface of the core, wherein the core comprises a fibrous matrix and absorbent material, wherein the fibrous matrix defines voids and passages between voids distributed substantially throughout the matrix;
wherein the absorbent material is located within some of the voids; and
wherein the absorbent material located within the voids is expandable into the voids. - View Dependent Claims (48, 49, 50, 51, 52, 53, 54, 113, 114)
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55. A method for forming an absorbent composite, comprising the steps of:
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combining resilient fibers, matrix fibers, and absorbent material in a dispersion medium to form a fibrous slurry;
depositing the fibrous slurry on a foraminous support;
withdrawing water from the deposited slurry to provide a wet composite having a fibrous stratum adjacent the support; and
drying the wet composite to form an absorbent composite having a core and a first and second fibrous strata, the core and strata being integrally formed, wherein the core is intermediate the first and second strata, wherein the first and second strata are coextensive with opposing surfaces of the core, wherein the core comprises a fibrous matrix and absorbent material, wherein the fibrous matrix defines voids and passages between voids distributed substantially throughout the matrix;
wherein the absorbent material is located within some of the voids; and
wherein the absorbent material located within the voids is expandable into the voids. - View Dependent Claims (56, 57, 58, 59, 60, 61, 62)
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63. A method for forming an absorbent composite, comprising the steps of:
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combining resilient fibers and matrix fibers in a first dispersion medium to form a first fibrous slurry;
combining absorbent material with a second dispersion medium to form an absorbent material slurry;
combining the absorbent material slurry with the first fibrous slurry to provide a second fibrous slurry;
depositing the second fibrous slurry on a foraminous support;
withdrawing water from the deposited slurry to provide a wet composite having a fibrous stratum adjacent the support; and
drying the wet composite to form an absorbent composite having a core and a fibrous stratum, the core and stratum being integrally formed, wherein the stratum is coextensive with a surface of the core, wherein the core comprises a fibrous matrix and absorbent material, wherein the fibrous matrix defines voids and passages between voids distributed substantially throughout the matrix;
wherein the absorbent material is located within some of the voids; and
wherein the absorbent material located within the voids is expandable into the voids. - View Dependent Claims (64, 65)
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66. A method for forming an absorbent composite, comprising the steps of:
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combining resilient fibers and matrix fibers in a first dispersion medium to form a first fibrous slurry;
combining absorbent material with a second dispersion medium to form an absorbent material slurry;
combining the absorbent material slurry with the first fibrous slurry to provide a second fibrous slurry;
depositing the second fibrous slurry on a foraminous support;
withdrawing water from the deposited slurry to provide a wet composite having a fibrous stratum adjacent the support; and
drying the wet composite to form an absorbent composite having a core and a first and second fibrous strata, the core and strata being integrally formed, wherein the core is intermediate the first and second strata, wherein the first and second strata are coextensive with opposing surfaces of the core, wherein the core comprises a fibrous matrix and absorbent material, wherein the fibrous matrix defines voids and passages between voids distributed substantially throughout the matrix;
wherein the absorbent material is located within some of the voids; and
wherein the absorbent material located within the voids is expandable into the voids. - View Dependent Claims (67, 68)
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69. A method for forming a fibrous web, comprising the steps of:
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(a) forming a first slurry comprising fibers in an aqueous dispersion medium;
(b) forming a second slurry comprising fibers in an aqueous dispersion medium;
(c) moving a first foraminous element in a first path;
(d) moving a second foraminous element in a second path;
(e) passing the first slurry into contact with the first foraminous element moving in the first path;
(f) passing the second slurry into contact with the second foraminous element moving in the second path;
(g) passing a third material between the first and second slurries, wherein the third material does not contact the foraminous elements; and
(h) withdrawing liquid from the first and second slurries and third material through the first and second foraminous elements to provide a fibrous web. - View Dependent Claims (70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83)
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84. A method for forming a fibrous web, comprising the steps of:
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(a) forming a first foam slurry comprising first fibers and a surfactant in an aqueous dispersion medium;
(b) forming a second foam slurry comprising second fibers and a surfactant in an aqueous dispersion medium;
(c) moving a first foraminous element in a first path;
(d) moving a second foraminous element in a second path;
(e) passing the first foam slurry into contact with the first foraminous element moving in the first path;
(f) passing the second foam slurry into contact with the second foraminous element moving in the second path;
(g) passing a third material between the first and second foam slurries, wherein the third material does not contact the foraminous elements; and
(h) withdrawing foam and liquid from the first and second foam slurries and third material through the first and second foraminous elements to provide a fibrous web. - View Dependent Claims (85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100)
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Specification