Absorbent article having a multilayer blended core and a method of forming

• US 20050033254A1
• Filed: 09/14/2004
• Published: 02/10/2005
• Est. Priority Date: 05/11/2001
• Status: Active Grant

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: David Arthur Fell, Jody Dorothy Suprise, William Anthony Georger
• Inventors: Georger, William Anthony, Suprise, Jody Dorothy, Fell, David Arthur
• Granted Patent: US 7,687,680 B2
• Time in Patent Office: Days
• US Class Current: 604/367
• CPC Class Codes: A61F 13/53418 having a C-folded cross-section
• 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 2013/53035 of cotton
• CPC Class Codes: A61F 2013/530364 of bamboo
• CPC Class Codes: D04H 5/06 strengthened or consolidated by welding-together thermoplastic fibres, filaments, or yarns

Abstract

An absorbent article, such as a thin incontinence pad or pantyliner, is disclosed which has an absorbent core formed from multiple layers of blended material for providing protection against involuntary urine loss. A method of forming the absorbent article is also disclosed. The absorbent article includes a liquid permeable bodyside liner, a liquid-impermeable baffle, and first and second absorbents positioned between the liner and the baffle. The first absorbent is a stabilized material containing a superabsorbent and has a predetermined basis weight. The second absorbent is also a stabilized material containing a superabsorbent. The second absorbent is positioned below the first absorbent and has a basis weight that is at least equal to the basis weight of the first absorbent.

Claims

1. (Canceled)

2. (Canceled)

3. An absorbent article, comprising:

a) a liquid permeable liner;

b) a liquid-impermeable baffle;

c) a first absorbent positioned between said liner and said baffle, said first absorbent being a stabilized material containing a superabsorbent, and having a predetermined basis weight; and

d) a second absorbent positioned between said first absorbent and said baffle, said second absorbent being a stabilized material containing a superabsorbent, and having a basis weight which is at least equal to said basis weight of said first absorbent.

4. The absorbent article of claim 3 wherein said first absorbent is an airlaid constructed of cellulosic fibers, a binder and a superabsorbent, and has a basis weight of from between about 100 gsm to about 600 gsm.

5. The absorbent article of claim 4 wherein said binder comprises binder fibers having a length of from between about 3 millimeters to about 6 millimeters.

6. The absorbent article of claim 3 wherein said second absorbent is an airlaid constructed of cellulosic fibers, a binder and a superabsorbent, and has a basis weight of from between about 100 gsm to about 600 gsm.

7. The absorbent article of claim 6 wherein said binder comprises binder fibers having a length of from between about 3 millimeters to about 6 millimeters.

8. The absorbent article of claim 3 wherein said second absorbent is folded.

9. The absorbent article of claim 3 wherein said second absorbent comprises two separate layers.

10. The absorbent article of claim 3 wherein said first and second absorbents are the same composition.

11. The absorbent article of claim 3 wherein said first and second absorbents have a combined thickness of less than about 4 millimeters.

42. The absorbent article of claim 3 wherein said basis weight of said second absorbent is greater than the basis weight of said first absorbent.

43. The absorbent article of claim 3 wherein said first absorbent layer is comprised of a blend of fibers including a first group of short, high denier hydrophilic fibers, and a second group of longer, lower denier, moisture insensitive crimped synthetic fibers, said second group of fibers making up at least about 5% of said first absorbent layer, by weight, and said first absorbent layer being compressed in a substantially dry condition to a density of at least about 0.09 g/cm³.

44. The absorbent article of claim 3 wherein said second absorbent layer is comprised of a blend of fibers including a first group of short, high denier hydrophilic fibers, and a second group of longer, lower denier, moisture insensitive crimped synthetic fibers, said second group of fibers making up at least about 5% of said second absorbent layer, by weight, and said second absorbent layer being compressed in a substantially dry condition to a density of at least about 0.09 g/cm³.

12. An absorbent article, comprising:

a) a liquid permeable liner;

b) a liquid-impermeable baffle;

c) a first absorbent positioned between said liner and said baffle, said first absorbent being a stabilized material containing a superabsorbent, and having a predetermined basis weight; and

d) a second absorbent positioned between said first absorbent and said baffle, said second absorbent being a stabilized material containing a superabsorbent, and having a basis weight which is at least equal to said basis weight of said first absorbent, and said second absorbent having a smaller surface area than said first absorbent.

13. The absorbent article of claim 12 wherein said first absorbent has a shaped configuration.

14. The absorbent article of claim 13 wherein said first absorbent has an asymmetrical configuration.

15. The absorbent article of claim 13 wherein said first absorbent has a dog bone shape.

16. The absorbent article of claim 12 having a fluid retention capacity of from between about 20 grams to about 100 grams.

17. The absorbent article of claim 12 having a fluid retention capacity of about 50 grams.

18. An absorbent article comprising:

a) a liquid permeable liner;

b) a liquid-impermeable baffle;

c) a first absorbent positioned between said liner and said baffle, said first absorbent being an airlaid material constructed of cellulosic fibers, a binder and superabsorbent particles, and having a basis weight of from between about 100 gsm to about 400 gsm; and

d) a second absorbent positioned between said first absorbent and said baffle, said second absorbent being an airlaid material constructed of cellulosic fibers, a binder and superabsorbent particles, and having a basis weight of from between about 200 gsm to about 600 gsm, said basis weight of said second absorbent being greater than said basis weight of said first absorbent, and said first and second absorbents are of similar composition.

19. The absorbent article of claim 18 wherein said superabsorbent particles contained in each of said first and second absorbents are the same composition.

20. The absorbent article of claim 18 wherein said second absorbent has a basis weight which is at least 1.5 times greater than said basis weight of said first absorbent.

21. The absorbent article of claim 20 wherein said second absorbent has a basis weight which is about 2 times greater than said basis weight of said first absorbent.

22. The absorbent article of claim 18 wherein said absorbent article has a thickness of from between about 3 millimeters to about 5 millimeters.

23. An absorbent article comprising:

a) a liquid permeable liner;

b) a liquid-impermeable baffle;

c) a transfer layer positioned adjacent to said liner which is capable of directing body fluid downward away from said liner;

d) a first absorbent positioned adjacent to said transfer layer, said first absorbent being an airlaid material constructed of cellulosic fibers, a binder and superabsorbent particles, and having a basis weight of from between about 100 gsm to about 400 gsm; and

e) a second absorbent positioned between said first absorbent and said baffle, said second absorbent being an airlaid material constructed of cellulosic fibers, a binder and superabsorbent, and having a basis weight of from between about 200 gsm to about 600 gsm, said basis weight of said second absorbent being greater than said basis weight of said first absorbent, and said first and second absorbents are of similar composition.

24. The absorbent article of claim 23 wherein said absorbent article has a thickness of less than about 5 millimeters.

25. The absorbent article of claim 23 wherein said first absorbent contains from between about 30% to about 85% cellulosic fibers, from between about 5% to about 20% binder fibers, and from between about 10% to about 60% superabsorbent.

26. The absorbent article of claim 23 wherein said second absorbent contains from between about 30% to about 85% cellulosic fibers, from between about 5% to about 20% binder fibers, and from between about 10% to about 60% superabsorbent.

27. The absorbent article of claim 23 wherein said binder comprises crimped binder fibers.

28. The absorbent article of claim 27 wherein said binder fibers are bicomponent fibers each having a polyester core surrounded by a polyethylene sheath.

29. The absorbent article of claim 27 wherein said binder fibers are bicomponent fibers each having a polypropylene core surrounded by a polyethylene sheath.

30. The absorbent article of claim 23 wherein said second absorbent has a basis weight which is a whole number multiple of the basis weight of said first absorbent.

31-37. -37. (Canceled)

38. An absorbent article, comprising:

a) a liquid permeable liner;

b) a liquid-impermeable baffle;

c) a first absorbent having a predetermined basis weight positioned between said liner and said baffle, said first absorbent being a stabilized material containing a superabsorbent and said first absorbent having a tensile strength of at least 12 Newtons per 50 millimeters; and

d) a second absorbent having a basis weight which is at least equal to said basis weight of said first absorbent positioned between said first absorbent and said baffle, said second absorbent being a stabilized material containing a superabsorbent and said second absorbent having a tensile strength of at least 12 Newtons per 50 millimeters.

39. An absorbent article, comprising:

a) a liquid permeable liner;

b) a liquid-impermeable baffle;

c) a first absorbent positioned between said liner and said baffle, said first absorbent being a stabilized material containing a superabsorbent, and having a predetermined basis weight, and said first absorbent having a tensile strength of at least 12 Newtons per 50 millimeters; and

d) a second absorbent positioned between said first absorbent and said baffle, said second absorbent being a stabilized material containing a superabsorbent, and having a basis weight which is at least equal to said basis weight of said first absorbent, said second absorbent having a smaller surface area than said first absorbent, and said second absorbent having a tensile strength of at least 12 Newtons per 50 millimeters.

40. An absorbent article comprising:

a) a liquid permeable liner;

b) a liquid-impermeable baffle;

c) a first absorbent positioned between said liner and said baffle, said first absorbent being an airlaid material constructed of cellulosic fibers, a binder and superabsorbent particles, and having a basis weight of from between about 100 gsm to about 400 gsm, and said first absorbent having a tensile strength of at least 12 Newtons per 50 millimeters; and

d) a second absorbent positioned between said first absorbent and said baffle, said second absorbent being an airlaid material constructed of cellulosic fibers, a binder and superabsorbent particles, and having a basis weight of from between about 200 gsm to about 600 gsm, said basis weight of said second absorbent being greater than said basis weight of said first absorbent, said second absorbent having a tensile strength of at least 12 Newtons per 50 millimeters, and said first and second absorbents are of similar composition.

41. An absorbent article comprising:

a) a liquid permeable liner;

b) a liquid-impermeable baffle;

c) a transfer layer positioned adjacent to said liner which is capable of directing body fluid downward away from said liner;

d) a first absorbent positioned adjacent to said transfer layer, said first absorbent being an airlaid material constructed of cellulosic fibers, a binder and superabsorbent particles, and having a basis weight of from between about 100 gsm to about 400 gsm, and said first absorbent having a tensile strength of at least 12 Newtons per 50 millimeters; and

e) a second absorbent positioned between said first absorbent and said baffle, said second absorbent being an airlaid material constructed of cellulosic fibers, a binder and superabsorbent, and having a basis weight of from between about 200 gsm to about 600 gsm, said basis weight of said second absorbent being greater than said basis weight of said first absorbent, said second absorbent having a tensile strength of at least 12 Newtons per 50 millimeters, and said first and second absorbents are of similar composition.