Absorbent articles containing absorbent cores having zoned absorbency and methods of making same

• US 7,759,540 B2
• Filed: 07/23/2002
• Issued: 07/20/2010
• Est. Priority Date: 07/23/2002
• Status: Expired due to Term

• Current Assignee: Paragon Trade Brands, LLC
• Original Assignee: Paragon Trade Brands, LLC
• Inventors: Baker, Andrew, Litvay, John
• Primary Examiner(s): Stephens; Jacqueline F.
• Application Number:
  US10/200,334
• Publication Number:
  US 20040019338A1
• Time in Patent Office: 2,919 Days
• Field of Search: 604/379, 604/380, 604/367, 604/378, 604/368, 604/382, 604/385.01, 442/375, 442/381, 442/393, 428/221
• US Class Current: 604/379
• 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 13/537 characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer A61F13/538 takes precedence
• CPC Class Codes: A61F 2013/53051 being only in particular parts or specially arranged
• CPC Class Codes: A61F 2013/53445 from several sheets

Abstract

The present invention relates generally to an absorbent core for an absorbent article, and more particularly to an absorbent core having zoned absorbency due to specific placement of adhesives or specific lack of adhesive. Such absorbent cores provide the flexibility of creating precise zoning of particular properties throughout the core, and they provide improved comfort and fit.

Claims

1. An absorbent article having a longitudinal dimension and a lateral dimension comprising:

a top sheet;

a back sheet; and

an absorbent laminate core disposed at least partially between the top sheet and the back sheet;

wherein the absorbent laminate core is comprised of;

an upper layer;

a lower layer, and

a central absorbent layer comprising a mixture of tow fibers and SAP disposed between the upper and lower layer,

an adhesive provided on an inner surface of at least one of said upper and lower layers, wherein said inner surface is disposed adjacent to said central absorbent layer therebetween, said adhesive provided at a predetermined location, said SAP being adhered to said adhesive on said inner surface to create higher concentrations of SAP at said predetermined location,

wherein the absorbent laminate core contains areas of varying absorbency due to said higher concentrations of SAP at said predetermined location,

wherein the upper and lower layer are comprised of the same material, and the material is selected from the group consisting of tissue, airlaid fluff pulp, synthetic non-woven material, and mixtures or combinations thereof, and

wherein the upper layer is fluid pervious, and the lower layer is fluid impervious.

2. The absorbent article of claim 1, whereby the article has a first waist region, a second waist region longitudinally opposed to the first waist region, and a crotch region between the first and second waist regions, the article further comprising at least one fastening element attached to a lateral edge of the first waist region;

and

one or more target devices attached to the article in the second waist region, where at least one fastening element and the one or more target devices are capable of attaching to one another, the one or more target devices being located so that the first waist region and second waist region of the garment may be joined to one another to secure the garment on a wearer.

3. The absorbent article of claim 2, further comprising elastic leg gathers comprising one or more elastic materials disposed adjacent a lateral edge of the crotch region, and standing leg gathers disposed on the top sheet adjacent the lateral edge of the crotch region.

4. The absorbent article of claim 2, wherein the at least one fastening element comprises a hook portion of a hook and loop fastener and the one or more target devices comprise the loop portion of a hook and loop fastener.

5. The absorbent article of claim 2, wherein the at least one fastening element is an adhesive tape and the one or more target devices comprise a tape receiving surface.

6. The absorbent article of claim 2, wherein the at least one fastening element is comprised of a pair of laterally extending tabs disposed on the lateral edges of the first waist region, whereby the laterally extending tabs each include at least one fastening element.

7. The absorbent article of claim 1, wherein at least one additional layer is disposed between the absorbent laminate core and the top sheet.

8. The absorbent article of claim 7, wherein the at least one additional layer is selected from the group consisting of a fluid acquisition layer, a distribution layer, an additional fibrous layer optionally containing SAP, a wicking layer, a storage layer, and combinations and fragments thereof.

9. The absorbent article of claim 1, wherein the absorbent laminate core includes at least one additional layer.

10. The absorbent article of claim 9, wherein the at least one additional layer is selected from the group consisting of a fluid acquisition layer, a distribution layer, an additional fibrous layer optionally containing SAP, a wicking layer, a storage layer, and combinations and fragments thereof.

11. The absorbent article of claim 1, wherein the absorbent laminate core is a multi-layered absorbent core unit including two outer tissue layers and a central fibrous layer that comprises from about 50% to about 95% by weight super absorbent polymer (SAP).

12. The absorbent article of claim 11, wherein the central fibrous layer comprises tow fibers selected from the group consisting of cellulose acetate fibers, rayon fibers, LYOCELL fibers, polyacrylonitrile fibers, cotton fibers and cotton linter fibers.

13. The absorbent article of claim 11, wherein the central fibrous layer further comprises up to 10% by weight fluff wood pulp fibers.

14. The absorbent article of claim 11, wherein the central fibrous layer further comprises particulate additives.

15. The absorbent article of claim 1, wherein the tow is a cellulose ester tow.

16. The absorbent article of claim 15, wherein the tow is a cellulose acetate tow.

17. The absorbent article of claim 1, wherein said predetermined location is only adjacent lateral edges of the laminate core.

18. The absorbent article of claim 1, further comprising a lateral center fold located at the approximate longitudinal center of the garment, wherein said predetermined location comprises a lateral center portion of the absorbent laminate core, and at a longitudinal position approximately 6 to about 12 cm from the center fold of the absorbent article.

19. The absorbent article of claim 1, further comprising a lateral center fold located at the approximate longitudinal center of the garment, wherein said predetermined location comprises a lateral center portion of the absorbent laminate core, and at a longitudinal position approximately 3 to about 8 cm from the center fold of the absorbent article.

20. The absorbent article of claim 1, wherein the tow is chemically modified tow.

21. An absorbent laminate core having a longitudinal dimension and a lateral dimension, the absorbent laminate core comprising:

an upper layer;

a lower layer, and

a central absorbent layer comprising a mixture of tow fibers and SAP disposed between the upper and lower layer,

an adhesive applied provided on an inner surface of at least one of said upper and lower layers, wherein in said inner surface is disposed adjacent to said central absorbent layer therebetween, said adhesive provided at a predetermined location on said inner surface, said SAP being adhered to said adhesive to create higher concentrations of SAP at said predetermined location, and

wherein the absorbent laminate core contains areas of varying absorbency due to said higher concentrations of SAP at said predetermined location.

22. An absorbent article having a longitudinal dimension and a lateral dimension comprising:

a top sheet;

a back sheet; and

an absorbent laminate core disposed at least partially between the top sheet and the back sheet;

wherein the absorbent laminate core is comprised of;

an upper layer;

a lower layer, and

a central absorbent layer comprising a mixture of tow fibers and SAP disposed between the upper and lower layer,

an adhesive disposed on an inner surface of at least one of said upper and lower layers, wherein said inner surface is disposed adjacent to said central absorbent layer therebetween, said adhesive provided at predetermined locations on said inner surface throughout a lateral cross-section of the laminate core, said SAP being adhered to said adhesive to create higher concentrations of SAP at said predetermined locations, and

wherein the absorbent laminate core contains areas of varying absorbency due to said higher concentrations of SAP at said predetermined locations throughout the lateral cross-section of the laminate core.

23. The absorbent article of claim 22, wherein said upper and lower layer are comprised of the same material, and the material is selected from the group consisting of tissue, airlaid fluff pulp, synthetic non-woven material, and mixtures or combinations thereof.

24. The absorbent article of claim 22, wherein said upper layer is fluid pervious and said lower layer is fluid impervious.

25. A method of making an absorbent laminate core having predetermined regions of higher concentrations of SAP, said method comprising:

a. disposing a mixture of fibers and SAP between upper and lower layers;

b. applying an adhesive at predetermined regions on an inner surface of at least one of said upper and lower layers; and

c. applying said adhesive prior to disposing said mixture of fibers and SAP between said upper and lower layers, such that SAP is adhered to said adhesive and create higher concentrations of SAP at said predetermined regions.