Absorbent article having superabsorbent in discrete pockets on a stretchable substrate

• US 6,610,900 B1
• Filed: 08/27/1999
• Issued: 08/26/2003
• Est. Priority Date: 08/27/1999
• Status: Expired due to Fees

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Tanzer, Richard Warren
• Primary Examiner(s): RUHL, DENNIS WILLIAM
• Application Number:
  US09/385,228
• Time in Patent Office: 1,460 Days
• Field of Search: 604/385.16, 604/364, 604/367, 604/368
• US Class Current: 604/368
• CPC Class Codes: A61F 13/49009 with elastic means
• CPC Class Codes: A61F 13/5323 having absorbent material located in discrete regions, e.g. pockets

Abstract

An absorbent article has a liquid permeable top sheet, a substantially liquid impermeable, preferably water vapor permeable back sheet, and a selectively stretchable absorbent composite between the top sheet and the back sheet. The selectively stretchable absorbent composite is more stretchable in a first direction than in a second direction perpendicular to the first direction, and can be stretched to at least 150% of an initial length in the first direction. The absorbent composite has a selectively stretchable substrate layer and a plurality of pockets in or on the substrate layer. The pockets each contain a quantity of superabsorbent material, which can swell when exposed to a liquid insult. When the substrate is stretched, the pockets become spaced further apart, thereby promoting comfort and alleviating gel blocking caused by adjacent pockets swelling toward each other.

Claims

1. An absorbent composite, comprising:

a selectively stretchable substrate which can be stretched to a greater extent in a first direction, and to a lesser extent in a second direction perpendicular to the first direction;

a plurality of pockets in or on the selectively stretchable substrate; and

a superabsorbent material in the pockets;

wherein the absorbent composite can be stretched to at least 150% of an initial length in the first direction, and only to less than 150% of an initial length in the second direction before breaking;

wherein the selectively stretchable substrate permits the pockets to push each other apart in a selected direction as the superabsorbent becomes wet and the pockets expand.

2. The absorbent composite of claim 1, wherein the composite can be stretched to at least 200% of the initial length in the first direction.

3. The absorbent composite of claim 1, wherein the composite can be stretched to at least 250% of the initial length in the first direction.

4. The absorbent composite of claim 1, wherein the composite can be stretched only to less than 125% of the initial length in the second direction.

5. The absorbent composite of claim 1, wherein the composite can be stretched only to less than 110% of the initial length in the second direction.

6. The absorbent composite of claim 1, wherein the substrate comprises a neck-bonded laminate of a neckable nonwoven web layer and an elastic layer.

7. The absorbent composite of claim 6, wherein the neckable nonwoven web comprises a spunbond web.

8. The absorbent composite of claim 6, wherein the neckable nonwoven web comprises a meltblown web.

9. The absorbent composite of claim 6, wherein the neckable nonwoven web comprises a bonded carded web.

10. The absorbent composite of claim 6, wherein the elastic layer comprises an elastic film.

11. The absorbent composite of claim 1, wherein the pockets are spaced apart at distances of about 0.05-1.5 inch (1.3-38 mm) from each other when the composite is not subjected to a stretching force.

12. The absorbent composite of claim 1, wherein the pockets are spaced apart at distances of about 0.10-1.0 inch (2.5-25 mm), when the composite is not subjected to a stretching force.

13. The absorbent composite of claim 1, wherein the pockets are spaced apart at distances of about 0.15-0.50 inch (3.8-13 mm), when the composite is not subjected to a stretching force.

14. The absorbent composite of claim 1, wherein the pockets have diameters of about 0.2-1.0 inch (5.1-25 mm) and depths of at least about 0.1 inch (2.5 mm), when the composite is not subjected to a stretching force.

15. The absorbent composite of claim 1, wherein the pockets have diameters of about 0.25-0.75 inch (6.4-19.1 mm) and depths of about 0.15-0.50 inch (3.8-13 mm), when the composite is not subjected to a stretching force.

16. A disposable absorbent article comprising a liquid permeable top sheet, a substantially liquid-impermeable back sheet, and an absorbent composite between the top sheet and the back sheet;

the absorbent composite including a selectively stretchable substrate which can be stretched to a greater extent in a first direction, and to a lesser extent in a second direction before breaking, the second direction being perpendicular to the first direction;

the absorbent composite firther including a plurality of pockets in or on the substrate material, and a superabsorbent material in the pockets;

wherein the selectively stretchable substrate permits the pockets to push each other apart in a selected direction as the superabsorbent becomes wet and the pockets expand.

17. The disposable absorbent article of claim 16, wherein the absorbent article is a diaper, and the first direction is a lateral direction extending between leg openings on a wearer.

18. The disposable absorbent garment of claim 16, wherein the absorbent composite can be stretched to at least 150% of an initial length in a first direction, and only to less than 150% of an initial length in a second direction perpendicular to the first direction.

19. The disposable absorbent article of claim 16, wherein the absorbent composite can be stretched to at least 200% of an initial length in a first direction, and only to less than 125% of an initial length in a second direction perpendicular to the first direction.

20. The disposable absorbent article of claim 16, wherein the absorbent composite can be stretched to at least 250% of an initial length in a first direction, and only to less than 110% of an initial length in a second direction perpendicular to the first direction.

21. The disposable absorbent article of claim 16, wherein the substrate comprises a neck-bonded laminate of a neckable nonwoven web and an elastic film.

22. The disposable absorbent article of claim 16, wherein the pockets together comprise about 1-100 grams of the superabsorbent.

23. The disposable absorbent article of claim 16, wherein the pockets together comprise about 3-50 grams of the superabsorbent.

24. The disposable absorbent article of claim 16, wherein the pockets together comprise about 5-15 grams of the superabsorbent.

25. The disposable absorbent article of claim 16, wherein the selectively stretchable substrate comprises the liquid permeable top sheet as a top layer of the substrate.

26. The disposable absorbent article of claim 16, wherein the selectively stretchable substrate comprises the substantially liquid-impermeable back sheet as a bottom laver of the substrate.

27. An absorbent article, comprising a liquid permeable top sheet, a substantially liquid impermeable back sheet, and an absorbent composite between the top sheet and the back sheet;

the absorbent composite including a neck-bonded laminate of a neckable nonwoven web and an elastic film;

the absorbent composite further including a plurality of pockets in or on the neck-bonded laminate, and superabsorbent material in the pockets;

wherein the absorbent composite can be stretched to at least 150% of an initial length in the first direction, and only to less than 150% of an initial length in the second direction before breaking;

wherein the neck-bonded laminate permits the pockets to push each other apart in a selected direction as the superabsorbent becomes wet and the pockets expand.

28. The absorbent article of claim 27, wherein the absorbent article is a diaper.

29. The absorbent article of claim 27, wherein the absorbent article is a training pant.

30. The absorbent article of claim 27, wherein the absorbent article is an adult incontinence garment.

31. The absorbent article of claim 27, wherein the absorbent article is swim wear.

32. The absorbent article of claim 27, wherein the absorbent article is a personal care absorbent article.

33. The absorbent article of claim 27, wherein the absorbent article is a medical absorbent article.