Absorbent article having discontinuous absorbent core

• US 6,802,834 B2
• Filed: 11/27/2002
• Issued: 10/12/2004
• Est. Priority Date: 01/15/2002
• Status: Expired due to Fees

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Olmstead, Paul E., Melius, Shannon K., Johnson, Eric D., Venturino, Michael B.
• Primary Examiner(s): Calvert, John J.
• Assistant Examiner(s): Bogart, Michael G.
• Application Number:
  US10/306,185
• Publication Number:
  US 20030139721A1
• Time in Patent Office: 685 Days
• Field of Search: 604/385.01, 604/385.31, 604/378, 604/382
• US Class Current: 604/385.31
• CPC Class Codes: A61F 13/15626 Making fibrous pads without outer layers
• CPC Class Codes: A61F 13/15634 Making fibrous pads between sheets or webs
• CPC Class Codes: A61F 13/4702 having a reinforcing member
• CPC Class Codes: A61F 13/534 having an inhomogeneous composition through the thickness of the pad A61F13/538, A61F13/539 take precedence; homogeneous cores with tissue wrapping A61F13/53
• 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 13/539 characterised by the connection of the absorbent layers with each other or with the outer layers
• CPC Class Codes: A61F 2013/53463 with a reinforcing structure, e.g. net

Abstract

An absorbent article is constructed with a discontinuous absorbent core strengthened by a reinforcing scrim material embedded in the absorbent material of the core. The scrim facilitates maintenance of the integrity of the core in use although the core may be weakened by the provision of ventilation openings or other discontinuities. The scrim also helps to keep the proper location of the absorbent core within the article. Moreover, use of scrim or other reinforcing material facilitates the manufacture of the absorbent core and of the absorbent article.

Claims

1. An absorbent structure for absorbing liquid in an absorbent article, the absorbent structure comprising an absorbent member made at least in part of an absorbent material, the absorbent member having at least one zone therein having a higher air permeability than an adjacent lower air permeability cone of the absorbent member, and a reinforcing member at least partially embedded in the absorbent member for reinforcing the absorbent member to hold its configuration under loads experienced by the absorbent structure.

2. An absorbent structure as set forth in claim 1 wherein the reinforcing member is adapted for passage of liquid through the reinforcing member.

3. An absorbent structure as set forth in claim 2 wherein the reinforcing member comprises a sheet of lofty nonwoven material.

4. An absorbent structure as set forth in claim 2 wherein the reinforcing member has openings therein for the passage of liquid.

5. An absorbent structure as set forth in claim 4 wherein the absorbent member has multiple higher air permeability zones, each higher air permeability zone comprising a passage in the absorbent member for passing air through the absorbent member, the passages of the absorbent member being out of registration with the openings of the reinforcing member.

6. An absorbent structure as set forth in claim 5 wherein a portion of the reinforcing member is exposed in at least some of the passages in the absorbent member.

7. An absorbent structure as set forth in claim 4 wherein the absorbent member has multiple higher air permeability zones, each higher air permeability zone comprising a passage in the absorbent member for passing air through the absorbent member, at least some of the passages of the absorbent member being in registration with the openings of the reinforcing member such that no portion of the reinforcing member is exposed in said at least some of the passages in the absorbent member.

8. An absorbent structure as set forth in claim 4 wherein the reinforcing member comprises strands arranged in a pattern in which at least some of the strands intersect one another at junctions, the strands being joined together where they intersect each other.

9. An absorbent structure as set forth in claim 8 wherein some of the strands extend generally lengthwise of the absorbent structure and some of the strands extend generally widthwise of the absorbent structure.

10. An absorbent structure as set forth in claim 9 wherein the absorbent member has multiple higher air permeability zones, each higher air permeability zone comprising a passage in the absorbent member for passing air through the absorbent member, the passages of the absorbent member being out of registration with the openings of the reinforcing member such that at least two longitudinally extending strands or at least two laterally extending strands are exposed in at least some of the passages.

11. An absorbent structure as set forth in claim 1 wherein the absorbent member has a length and a width, and wherein no portion of the reinforcing member projects laterally outwardly of the absorbent member.

12. An absorbent structure as set forth in claim 11 wherein no portion of the reinforcing member is exposed outside a perimeter of the absorbent member.

13. An absorbent structure as set forth in claim 1 wherein each higher air permeability zone comprises a passage in the absorbent member, at least portions of the absorbent member being spaced apart from each other across the passage.

14. An absorbent structure as set forth in claim 13 wherein the absorbent member comprises at least two distinct, spaced apart sections of absorbent material, and wherein the passage defines a gap spacing apart the at least two absorbent member sections, the absorbent material of each section being free of contact with the absorbent material of the other section, the reinforcing member bridging the gap for interconnecting the sections.

15. An absorbent structure as set forth in claim 14 wherein the absorbent member sections extend lengthwise of the absorbent structure, the gap spacing the absorbent member sections laterally of each other.

16. An absorbent structure as set forth in claim 14 wherein the absorbent member sections extend widthwise of the absorbent structure, the gap spacing the absorbent member sections lengthwise of the absorbent structure.

17. An absorbent structure as set forth in claim 13 wherein the absorbent member comprises multiple passages.

18. An absorbent structure as set forth in claim 17 wherein each passage extends through the absorbent member and opens on generally opposite sides of the absorbent member.

19. An absorbent member as set forth in claim 1 wherein said at least one zone of higher air permeability comprises a lower basis weight region of the absorbent member.

20. An absorbent member as set forth in claim 19 wherein each lower basis weight region comprises a dimple extending inwardly from one major surface of the absorbent member.

21. An absorbent structure as set forth in claim 1 wherein the reinforcing member comprises spaced apart components unconnected to each other except through connection with the absorbent member.

22. An absorbent structure as set forth in claim 21 wherein each component has projecting elements extending outwardly therefrom.

23. An absorbent structure as set forth in claim 22 wherein each projecting element comprises a multiplicity of filaments.

24. An absorbent structure as set forth in claim 22 wherein each projecting element comprises a cross piece arranged generally perpendicularly to the component.

25. An absorbent structure as set forth in claim 22 wherein each projecting element comprises a knob.

26. An absorbent structure as set forth in claim 1 wherein said at least one higher air permeability zone forms about 5% to 75% of the area of at least one major surface of the absorbent structure.

27. An absorbent article adapted to be worn by a wearer for absorbing body exudates, the absorbent article comprising a liquid permeable liner, a backsheet layer and an absorbent structure as set forth in claim 1.

28. An absorbent article as set forth in claim 27 having a skin hydration value of less than about 18 grams per square meter per hour.

29. An absorbent article as set forth in claim 28 having a skin hydration value of less than about 15 grams per square meter per hour.

30. An absorbent article as set forth in claim 27 further comprising a spacer layer comprising a hydrophobic, nonwoven material having a thickness of at least about 0.10 centimeters and a basis weight of from about 20 to about 120 grams per square meter.

31. An absorbent article as set forth in claim 27 further comprising a surge management layer located between the liner and backsheet layer, the surge management layer comprising a nonwoven material having a basis weight of from 5 about 20 to about 300 grams per square meter.

32. An absorbent structure for absorbing liquid in an absorbent article, the absorbent structure comprising an absorbent member made at least in part of an absorbent material, the absorbent member having at least one void defined therein, at least some absorbent material of the absorbent member being spaced apart across said void, and a reinforcing member at least partially embedded in the absorbent member for reinforcing the absorbent member to maintain its integrity under loads experienced by the absorbent structure.

33. An absorbent structure as set forth in claim 32 wherein the void defines a liquid collection volume for collecting a volume of liquid applied rapidly to the absorbent structure for subsequent absorption into the absorbent member.

34. An absorbent structure as set forth in claim 32 wherein the reinforcing member is at least partially in registration with the void.

35. An absorbent structure as set forth in claim 34 wherein the reinforcing member extends through the void.

36. An absorbent structure as set forth in claim 34 wherein the reinforcing member is entirely embedded within the absorbent member.

37. An absorbent structure as set forth in claim 32 wherein the void is enclosed within the absorbent member.

38. An absorbent structure as set forth in claim 32 wherein the void opens outwardly of the absorbent member on one side thereof.

39. An absorbent structure as set forth in claim 32 further comprising a surge member located at least partially in the void.

40. An absorbent structure as set forth in claim 39 where in the surge member substantially fills the void.

41. An absorbent structure for absorbing liquid in an absorbent article, the absorbent structure comprising an absorbent member made at least in part of an absorbent material, the absorbent member having at least one zone therein having a higher air permeability than an adjacent lower air permeability zone of the absorbent member, and a reinforcing member for reinforcing the absorbent member to hold its configuration under loads experienced by the absorbent structure, the reinforcing member having an inner face and an outer face, at least a portion of the reinforcing member being secured within the absorbent member with the inner face and the outer face of the reinforcing member at said portion thereof being substantially overlaid by the absorbent member.