Absorbent articles containing absorbent cores having zoned absorbency and methods of making same

• US 20040019338A1
• Filed: 07/23/2002
• Published: 01/29/2004
• Est. Priority Date: 07/23/2002
• Status: Active Grant

• Current Assignee: Paragon Trade Brands, LLC
• Original Assignee: Paragon Trade Brands Inc. (Johnson Controls International plc)
• Inventors: Baker, Andrew, Litvay, John
• Granted Patent: US 7,759,540 B2
• Time in Patent Office: Days
• US Class Current: 604/367
• 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 13/537 characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer A61F13/538 takes precedence
• CPC Class Codes: A61F 2013/53051 being only in particular parts or specially arranged
• CPC Class Codes: A61F 2013/53445 from several sheets

Abstract

The present invention relates generally to an absorbent core for an absorbent article, and more particularly to an absorbent core having zoned absorbency due to specific placement of adhesives or specific lack of adhesive. Such absorbent cores provide the flexibility of creating precise zoning of particular properties throughout the core, and they provide improved comfort and fit.

Claims

1. An absorbent article having a longitudinal dimension and a lateral dimension comprising:

a top sheet;

a back sheet; and

a absorbent laminate core disposed at least partially between the top sheet and the back sheet;

wherein the absorbent laminate core is comprised of;

an upper layer;

a lower layer; and

a central absorbent layer including a mixture of tow fibers and SAP disposed between the upper and lower layer, and wherein the absorbent laminate core contains areas of varying absorbency due to varying concentrations of SAP throughout the cross-section of the laminate core.

2. The absorbent article of claim 1, whereby the article has a first waist region, a second waist region longitudinally opposed to the first waist region, and a crotch region between the first and second waist regions, the article further comprising at least one fastening element attached to a lateral edge of the first waist region;

and

one or more target devices attached to the article in the second waist region, where at least one fastening element and the one or more target devices are capable of attaching to one another, the one or more target devices being located so that the first waist region and second waist region of the garment may be joined to one another to secure the garment on a wearer.

3. The absorbent article of claim 2, further comprising elastic leg gathers comprising one or more elastic materials disposed adjacent a lateral edge of the crotch region, and standing leg gathers disposed on the top sheet adjacent the lateral edge of the crotch region.

4. The absorbent article of claim 2, wherein the at least one fastening element comprises a hook portion of a hook and loop fastener and the one or more target devices comprise the loop portion of a hook and loop fastener.

5. The absorbent article of claim 2, wherein the at least one fastening element is an adhesive tape and the one or more target devices comprise a tape receiving surface.

6. The absorbent article of claim 2, wherein the at least one fastening element is comprised of a pair of laterally extending tabs disposed on the lateral edges of the first waist region, whereby the laterally extending tabs each include at least one fastening element.

7. The absorbent article of claim 1, wherein at least one additional layer is disposed between the absorbent laminate core and the top sheet.

8. The absorbent article of claim 7, wherein the at least one additional layer is selected from the group consisting of a fluid acquisition layer, a distribution layer, an additional fibrous layer optionally containing SAP, a wicking layer, a storage layer, and combinations and fragments thereof.

9. The absorbent article of claim 1, wherein the absorbent laminate core includes at least one additional layer.

10. The absorbent article of claim 9, wherein the at least one additional layer is selected from the group consisting of a fluid acquisition layer, a distribution layer, an additional fibrous layer optionally containing SAP, a wicking layer, a storage layer, and combinations and fragments thereof.

11. The absorbent article of claim 1, wherein the absorbent laminate core is a multi-layered absorbent core unit including two outer tissue layers and a central fibrous layer that comprises from about 50% to about 95% by weight super absorbent polymer (SAP).

12. The absorbent article of claim 11, wherein the central fibrous layer comprises tow fibers selected from the group consisting of cellulose acetate fibers, rayon fibers, LYOCELL fibers, polyacrylonitrile fibers, cotton fibers and cotton linter fibers.

13. The absorbent article of claim 11, wherein the central fibrous layer further comprises up to 10% by weight fluff wood pulp fibers.

14. The absorbent article of claim 11, wherein the central fibrous layer further comprises particulate additives.

15. The absorbent article of claim 1, wherein the tow is a cellulose ester tow.

16. The absorbent article of claim 15, wherein the tow is a cellulose acetate tow.

17. The absorbent article of claim 1, wherein the upper and lower layer are comprised of the same material, and the material is selected from the group consisting of tissue, airlaid fluff pulp, synthetic non-woven material, and mixtures or combinations thereof.

18. The absorbent article of claim 17, wherein the upper layer is fluid pervious, and the lower layer is fluid impervious.

19. The absorbent article of claim 1, wherein the absorbent laminate core comprises adhesives applied only in its lateral edges.

20. The absorbent article of claim 1, wherein adhesive is applied to the upper layer and/or the lower layer in the lateral center portion of the absorbent laminate core, and at a longitudinal position approximately 6 to about 12 cm from the center fold of the garment.

21. The absorbent article of claim 1, wherein adhesive is applied to the upper layer and/or the lower layer in the lateral center portion of the absorbent laminate core, and at a longitudinal position approximately 3 to about 8 cm from the center fold of the garment.

22. The absorbent article of claim 1, wherein no adhesive is applied to the upper layer, lower layer, or central fibrous layer when making the absorbent laminate core.

23. The absorbent article of claim 20, wherein the lateral edges of the absorbent laminate core are crimped.

24. The absorbent article of claim 20, wherein the longitudinal edges of the absorbent laminate core are crimped.

25. The absorbent article of claim 1, wherein the tow is chemically modified tow.

26. An absorbent laminate comprising:

an upper layer;

a lower layer; and

a central absorbent layer including a mixture of tow fibers and SAP disposed between the upper and lower layer,

wherein the absorbent laminate contains areas of varying absorbency due to varying concentrations of SAP throughout the cross-section of the laminate.

27. The absorbent laminate of claim 26, further comprising at least one additional layer.

28. The absorbent laminate of claim 27, wherein the at least one additional layer is selected from the group consisting of a fluid acquisition layer, a distribution layer, an additional fibrous layer optionally containing SAP, a wicking layer, a storage layer, and combinations and fragments thereof.

29. The absorbent laminate of claim 26, comprising two outer tissue layers and a central fibrous layer that comprises from about 50% to about 95% by weight super absorbent polymer (SAP).

30. The absorbent laminate of claim 26, wherein the central absorbent layer comprises tow fibers selected from the group consisting of cellulose acetate fibers, rayon fibers, LYOCELL fibers, polyacrylonitrile fibers, cotton fibers and cotton linter fibers.

31. The absorbent laminate of claim 26, wherein the central absorbent layer further comprises up to 10% by weight fluff wood pulp fibers.

32. The absorbent laminate of claim 26, wherein the central absorbent layer further comprises particulate additives.

33. The absorbent laminate of claim 26, wherein the tow is a cellulose ester tow.

34. The absorbent laminate claim 26, wherein the tow is a cellulose acetate tow.

35. The absorbent laminate of claim 26, wherein the upper and lower layer are comprised of the same material, and the material is selected from the group consisting of tissue, airlaid fluff pulp, synthetic non-woven material, and mixtures or combinations thereof.

36. The absorbent laminate of claim 26, wherein the upper layer is fluid pervious, and the lower layer is fluid impervious.

37. The absorbent laminate of claim 26, wherein adhesives are applied only in its lateral edges.

38. The absorbent laminate of claim 26, wherein adhesive is applied to the upper layer and/or the lower layer in the lateral center portion of the absorbent laminate, and at a longitudinal position approximately 6 to about 12 cm from the center fold.

39. The absorbent laminate of claim 26, wherein adhesive is applied to the upper layer and/or the lower layer in the lateral center portion of the absorbent laminate core, and at a longitudinal position approximately 3 to about 8 cm from the center fold of the garment.

40. The absorbent laminate of claim 26, wherein no adhesive is applied to the upper layer, lower layer, or central fibrous layer when making the absorbent laminate core.

41. The absorbent laminate of claim 37, wherein the lateral edges of the absorbent laminate are crimped.

42. The absorbent laminate of claim 26, wherein longitudinal edges of the absorbent laminate are crimped.

43. The absorbent laminate of claim 26, wherein the tow is chemically modified tow.

44. A method of making an absorbent article comprising:

a) preparing a top sheet and a back sheet;

b) preparing an absorbent laminate core by;

b1) providing an upper layer;

b2) providing a lower layer;

b3) providing a central absorbent layer that comprises a mixture of tow fibers and superabsorbent polymer (SAP); and

b4) disposing the central absorbent layer at least partially between the upper layer and the lower layer; and

c) disposing the absorbent laminate core at least partially between the top sheet and the back sheet,

whereby the absorbent laminate core is prepared in such a manner that it contains areas of varying absorbency due to varying concentrations of SAP throughout the cross-section of the laminate core.

45. The method of claim 44, wherein preparing the absorbent laminate core further comprises supplying select regions of adhesive to at least one of the upper and lower layers prior to disposing the central absorbent layer at least partially between the upper layer and the lower layer.

46. The method of claim 44, wherein preparing the absorbent laminate core comprises supplying no adhesive to the upper or lower layer thereby providing a gravitationally zoned absorbent laminate core.

47. The method of claim 44, further comprising disposing at least one additional layer between the absorbent laminate core and the top sheet.

48. The method of claim 47, wherein the at least one additional layer is selected from the group consisting of a fluid acquisition layer, a distribution layer, an additional fibrous layer optionally containing SAP, a wicking layer, a storage layer, and combinations and fragments thereof.

49. The method of claim 44, wherein the central layer comprises from about 50% to about 95% by weight super absorbent polymer (SAP).

50. The method of claim 44, wherein the central layer comprises tow fibers selected from the group consisting of cellulose acetate fibers, rayon fibers, LYOCELL fibers, polyacrylonitrile fibers, cotton fibers and cotton linter fibers.

51. The method of claim 50, wherein the tow is a cellulose ester tow.

52. The method of claim 44, wherein the upper and lower layer are comprised of the same material, and the material is selected from the group consisting of tissue, airlaid fluff pulp, synthetic non-woven material, and mixtures or combinations thereof.

53. The method of claim 44, wherein the upper layer is fluid pervious, and the lower layer is fluid impervious.

54. The method of claim 45, wherein the select regions of adhesives are applied at the lateral edges of the absorbent laminate core.

55. The method of claim 45, wherein the select regions of adhesives are applied to the upper layer and/or the lower layer in the lateral center portion of the absorbent laminate core, and at a longitudinal position approximately 6 to about 12 cm from the center fold of the absorbent article.

56. The method of claim 45, wherein the select regions of adhesives are applied to the upper layer and/or the lower layer in the lateral center portion of the absorbent laminate core, and at a longitudinal position approximately 3 to about 8 cm from the center fold of the garment.

57. The method of claim 44, wherein no adhesive is applied to the upper layer, lower layer, or central absorbent layer when making the absorbent laminate core.

58. The method of claim 54, further comprising crimping the lateral edges of the absorbent laminate core.

59. The method of claim 44, further comprising cutting the absorbent laminate core prior to disposing it at least partially between the upper and lower layer such that the absorbent laminate core has lateral and longitudinal edges.

60. The method of claim 59, further comprising crimping the longitudinal edges of the absorbent laminate core.

61. The method of claim 44, wherein the tow is chemically modified tow.

62. A method of making an absorbent laminate comprising:

providing an upper layer;

providing a lower layer;

providing a central absorbent layer that comprises a mixture of tow fibers and superabsorbent polymer (SAP); and

disposing the central absorbent layer at least partially between the upper layer and the lower layer,

whereby the absorbent laminate is prepared in such a manner that it contains areas of varying absorbency due to varying concentrations of SAP throughout the cross-section of the absorbent laminate.

63. The method of claim 62, further comprises supplying select regions of adhesive to at least one of the upper and lower layers prior to disposing the central absorbent layer at least partially between the upper layer and the lower layer.

64. The method of claim 62, wherein preparing the absorbent laminate comprises supplying no adhesive to the upper or lower layer thereby providing a gravitationally zoned absorbent laminate core.

65. The method of claim 62, wherein the central absorbent layer comprises from about 50% to about 95% by weight super absorbent polymer (SAP).

66. The method of claim 62, wherein the central absorbent layer comprises tow fibers selected from the group consisting of cellulose acetate fibers, rayon fibers, LYOCELL fibers, polyacrylonitrile fibers, cotton fibers and cotton linter fibers.

67. The method of claim 66, wherein the tow is a cellulose ester tow.

68. The method of claim 62, wherein the upper and lower layer are comprised of the same material, and the material is selected from the group consisting of tissue, airlaid fluff pulp, synthetic non-woven material, and mixtures or combinations thereof.

69. The method of claim 62, wherein the upper layer is fluid pervious, and the lower layer is fluid impervious.

70. The method of claim 63, wherein the select regions of adhesives are applied at lateral edges of the absorbent laminate.

71. The method of claim 63, wherein the select regions of adhesives are applied to the upper layer and/or the lower layer in the lateral center portion of the absorbent laminate, and at a longitudinal position approximately 6 to about 12 cm from the center fold of the absorbent laminate.

72. The method of claim 63, wherein the select regions of adhesives are applied to the upper layer and/or the lower layer in the lateral center portion of the absorbent laminate, and at a longitudinal position approximately 3 to about 8 cm from the center fold of the absorbent laminate.

73. The method of claim 62, wherein no adhesive is applied to the upper layer, lower layer, or central absorbent layer when making the absorbent laminate.

74. The method of claim 70, further comprising crimping the lateral edges of the absorbent laminate.

75. The method of claim 62, further comprising cutting the absorbent laminate such that the absorbent laminate has lateral and longitudinal edges.

76. The method of claim 75, further comprising crimping the longitudinal edges of the absorbent laminate.

77. The method of claim 62, wherein the tow is chemically modified tow.