Absorbent article having superabsorbent pockets in a non-absorbent carrier layer

• US 6,429,350 B1
• Filed: 08/27/1999
• Issued: 08/06/2002
• Est. Priority Date: 08/27/1999
• Status: Expired due to Term

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Shafer, Bruce Reed, Tanzer, Richard Warren
• Primary Examiner(s): Weiss, John G.
• Assistant Examiner(s): BOGART, MICHAEL G
• Application Number:
  US09/385,514
• Time in Patent Office: 1,075 Days
• Field of Search: 604/385.16, 604/364, 604/367, 604/368, 604/378
• US Class Current: 604/368
• CPC Class Codes: A61F 13/5323 having absorbent material located in discrete regions, e.g. pockets
• CPC Class Codes: A61F 13/53747 the layer is facing the topsheet layer is part of the topsheet A61F13/511
• CPC Class Codes: A61F 2013/530481 having superabsorbent materials, i.e. highly absorbent polymer gel materials
• CPC Class Codes: A61F 2013/53765 characterized by its geometry

Abstract

An absorbent article having relatively light weight and less bulk includes a liquid permeable top layer, an inner surge layer, and a substantially liquid-impermeable outer cover. A plurality of pockets are formed in at least one of the surge layer and the outer cover material. The pockets contain a superabsorbent material. The surge layer or outer cover material containing the pockets functions as an absorbent layer, thereby eliminating the need for a separate (often bulky) absorbent layer between the surge layer and the outer cover.

Claims

1. An absorbent article, comprising:

a liquid-permeable body-side liner;

a non-absorbent surge material abutting the body-side liner;

an outer cover of a substantially liquid-impermeable non-absorbent outer cover material abutting the surge material;

a plurality of pockets in at least one of the surge material or the outer cover material; and

a superabsorbent material in at least some of the pockets.

2. The absorbent article of claim 1, wherein the pockets are formed in the surge material.

3. The absorbent article of claim 1, wherein the pockets have depths of at least about 0.1 inch (2.5 mm), and diameters of about 0.2-1.0 inch (5-25 mm).

4. The absorbent article of claim 1, wherein the pockets have depths of about 0.15-0.50 inch (3.8-13 mm), and diameters of about 0.25-0.75 inch (6.4-19 mm).

5. The absorbent article of claim 1, wherein the pockets have depths of about 0.20-0.30 inch (5.1-7.6 mm), and diameters of about 0.40-0.60 inch (10-15 mm).

6. The absorbent article of claim 1, wherein the pockets are spaced apart at distances of about 0.05-1.5 inch (1.3-38 mm).

7. The absorbent article of claim 1, wherein the pockets are spaced apart at distances of about 0.10-1.0 inch (2.5-25 mm).

8. The absorbent article of claim 1, wherein the pockets are spaced apart at distances of about 0.15-0.50 inch (3.8-13 mm).

9. The absorbent article of claim 1, wherein each pocket comprises about 25-500 mg of the superabsorbent.

10. The absorbent article of claim 1, wherein each pocket comprises about 50-300 mg of the superabsorbent.

11. The absorbent article of claim 1, wherein each pocket comprises about 100-200 mg of the superabsorbent.

12. An absorbent article, comprising:

a liquid permeable body-side liner;

a surge material, formed of a non-absorbent material;

a substantially liquid-impermeable outer cover, formed of a non-absorbent outer cover material;

a plurality of pockets in at least one of the surge material and the outer cover material; and

a superabsorbent material in at least some of the pockets;

wherein the absorbent article is devoid of a separate absorbent layer between the surge material and the outer cover material.

13. The absorbent article of claim 12, wherein the pockets are formed in the surge material.

14. The absorbent article of claim 12, wherein the material in which the pockets are formed comprises a thermoplastic polymer.

15. The absorbent article of claim 12, wherein the material in which the pockets are formed comprises a thermoplastic nonwoven fibrous web.

16. The absorbent article of claim 15, wherein the nonwoven web comprises a neck-stretched nonwoven web.

17. The absorbent article of claim 13, wherein the surge material comprises a nonwoven fibrous web.

18. The absorbent article of claim 12, wherein the outer cover material comprises a nonwoven fibrous web and a breathable thermoplastic film.

19. An absorbent article, comprising:

a non-absorbent surge material including at least one layer of a fibrous non-absorbent material;

a non-absorbent outer cover material abutting the surge material and including at least one other layer of a fibrous non-absorbent material;

a plurality of pockets in at least one of the surge material or the outer cover material; and

a superabsorbent material in at least some of the pockets.

20. The absorbent article of claim 19, comprising a diaper.

21. The absorbent article of claim 19, comprising training pants.

22. The absorbent article of claim 19, comprising swim wear.

23. The absorbent article of claim 19, comprising absorbent underpants.

24. The absorbent article of claim 19, comprising a baby wipe.

25. The absorbent article of claim 19, comprising an adult incontinence product.

26. The absorbent article of claim 19, comprising a feminine hygiene product.

27. The absorbent article of claim 19, comprising a medical absorbent product.