Absorbent layer, structure and article along with a method of forming the same
First Claim
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1. An absorbent layer capable of absorbing a fluid, comprising:
- a) a three-dimensional fabric having a density of less than about 0.05 g/cc, a first surface, first and second ends and first and second side edges;
b) a liquid adhesive applied to said first surface of said fabric in a non-continuous fashion to obtain an adhesive zone and adhesive free zones, at least two of said adhesive free zones extending from said first end to said second end and each being aligned adjacent to one of said first and second side edges; and
c) a superabsorbent in particle form having an Absorbency Under Load (AUL) value of greater than about 13 g/g measured at 0.6 psi, and said superabsorbent is positioned on said liquid adhesive.
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Abstract
An absorbent layer is disclosed which is capable of absorbing a fluid and which maintains the superabsorbent particles, powder or fibers in a predetermined position. The absorbent layer is constructed of a bulky, three-dimensional fabric which has a liquid adhesive applied thereto in a non-continuous fashion. A superabsorbent is then positioned on the liquid adhesive. The absorbent layer can be secured to a liquid-impermeable outer cover to form a disposable absorbent article. A method of forming the absorbent layer is also disclosed. Furthermore, a method of forming a disposable absorbent article using the absorbent layer is described.
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Citations
29 Claims
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1. An absorbent layer capable of absorbing a fluid, comprising:
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a) a three-dimensional fabric having a density of less than about 0.05 g/cc, a first surface, first and second ends and first and second side edges; b) a liquid adhesive applied to said first surface of said fabric in a non-continuous fashion to obtain an adhesive zone and adhesive free zones, at least two of said adhesive free zones extending from said first end to said second end and each being aligned adjacent to one of said first and second side edges; and c) a superabsorbent in particle form having an Absorbency Under Load (AUL) value of greater than about 13 g/g measured at 0.6 psi, and said superabsorbent is positioned on said liquid adhesive. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A two layered structure, comprising:
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a) an absorbent layer capable of absorbing a fluid, said absorbent layer including a three-dimensional fabric having a density of less than about 0.03 g/cc and having a first surface, first and second ends and first and second side edges, a liquid adhesive applied to said first surface of said fabric in a non-continuous fashion to obtain adhesive zones and adhesive free zones, at least two of said adhesive free zones extending from said first end to said second end and each being aligned adjacent to one of said first and second side edges, each of said adhesive free zones having a width of at least about 2 millimeters, and a superabsorbent is positioned on said liquid adhesive; and b) a liquid-impermeable outer cover positioned adjacent to said first surface of said fabric and being bonded to at least one of said adhesive free zones. - View Dependent Claims (13, 14, 15, 16)
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17. A method of forming an absorbent layer comprising the steps of:
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a) utilizing a three-dimensional fabric having a density of less than about 0.05 g/cc, a longitudinal central axis, a first surface, first and second ends, and first and second side edges; b) applying a liquid adhesive onto said first surface of said fabric in a non-continuous fashion perpendicular to said longitudinal central axis to obtain an adhesive zone and adhesive free zones, two of said adhesive free zones extending from said first end to said second end and each being aligned adjacent to one of said first and second side edges, and a third adhesive free zone is located between said two adhesive free zones; c) depositing a superabsorbent onto said liquid adhesive; d) compacting said superabsorbent into said liquid adhesive to adhere said superabsorbent to said fabric; and e) cutting said fabric to form said absorbent layer. - View Dependent Claims (18, 19, 20)
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21. A method of forming a two layered structure comprising the steps of:
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a) utilizing an absorbent layer formed from a three-dimensional fabric, said fabric having a density of less than about 0.05 g/cc, a longitudinal central axis, a first surface, first and second ends, and first and second side edges; b) applying a liquid adhesive onto said first surface of said fabric in a non-continuous fashion and perpendicular to said longitudinal central axis to obtain adhesive zones and adhesive free zones, two of said adhesive free zones extending from said first end to said second end and each being aligned adjacent to one of said first and second side edges; c) depositing a superabsorbent onto said liquid adhesive; d) compacting said superabsorbent into said liquid adhesive to adhere said superabsorbent to said fabric; e) positioning a liquid-impermeable outer cover adjacent to said first surface of said absorbent layer; f) bonding said liquid-impermeable outer cover to said absorbent layer by forming a seal aligned with at least a portion of said adhesive free zones; and g) cutting both said absorbent layer and said outer cover to form said disposable absorbent article. - View Dependent Claims (22, 23, 24)
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25. A disposable absorbent article comprising:
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a) a bodyside cover having an enlarged aperture formed therethrough; b) an absorbent layer formed from a three-dimensional fabric, said fabric having a density of less than about 0.05 g/cc, a longitudinal central axis, a first surface, first and second ends, and first and second side edges, a liquid adhesive applied onto said first surface in a non-continuous fashion and perpendicular to said longitudinal central axis to obtain adhesive zones and adhesive free zones, two of said adhesive free zones extending from said first end to said second end and each being aligned adjacent to one of said first and second side edges, and a superabsorbent secured to said liquid adhesive; c) a liquid-impermeable outer cover positioned adjacent to said first surface of said absorbent layer; and d) a seal aligned with at least a portion of said adhesive free zones which secures said bodyside cover, said absorbent layer and said outer cover together to form said disposable absorbent article. - View Dependent Claims (26, 27, 28, 29)
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Specification