Absorbent core for disposable absorbent article

• US 9,358,705 B2
• Filed: 03/28/2011
• Issued: 06/07/2016
• Est. Priority Date: 03/05/2007
• Status: Active Grant

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Zhao, Jean Jianqun, Noel, John Richard, McAffry, Karen Denise, Gilbertson, Gary Wayne, Gray, Brian Francis, Arora, Kelyn Anne
• Primary Examiner(s): Musser, Barbara J
• Application Number:
  US13/073,185
• Publication Number:
  US 20110174430A1
• Time in Patent Office: 1,898 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: A61F 13/15699 Forming webs by bringing together several webs, e.g. by laminating or folding several webs, with or without additional treatment of the webs
• CPC Class Codes: A61F 13/15723 Partitioning batts; Cutting
• CPC Class Codes: B29C 2043/464 having projections or knives, e.g. for cutting-out or for forming local depressions
• CPC Class Codes: B29C 43/222 characterised by the shape of the surface
• CPC Class Codes: B29C 43/46 Rollers
• CPC Class Codes: B29C 59/046 for layered or coated substantially flat surfaces
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29K 2313/00 Use of textile products or fabrics as reinforcement B29K2105/06 takes precedence
• CPC Class Codes: B29K 2995/0065 Permeability to gases
• CPC Class Codes: B29L 2031/4878 Diapers, napkins
• CPC Class Codes: B30B 11/165 Roll constructions
• CPC Class Codes: B30B 11/18 using profiled rollers
• CPC Class Codes: B30B 3/005 Roll constructions
• CPC Class Codes: Y10T 156/1007 Running or continuous length work
• CPC Class Codes: Y10T 156/101 Prior to or during assembly with additional lamina
• CPC Class Codes: Y10T 156/102 with deformation or cutting of corrugated lamina
• CPC Class Codes: Y10T 156/1074 Separate cutting of separate sheets or webs

Abstract

A method of making an absorbent core for use in an absorbent article. The method comprising the steps of:

• • a. providing a first absorbent fibrous web material;
  • b. providing a second absorbent fibrous web material;
  • c. providing a pair of rolls forming a nip through which the first and second absorbent fibrous web materials can be processed, the pair of rolls being selected from the processes consisting of, ring rolling, SELF, micro-SELF, and rotary knife aperturing;
  • d. deforming portions of the first absorbent fibrous web material by processing through the pair of rolls;
  • e. deforming portions of the second absorbent fibrous web material by processing through the pair of rolls; and
  • f. combining the first and second absorbent fibrous web materials to form the absorbent core.

Claims

1. A method of making an absorbent core for use in an absorbent article, said method comprising the steps of:

a. providing a first fibrous web material;

b. providing a second fibrous web material;

c. providing a pair of rolls forming a nip through which said first fibrous web material can be processed, said pair of rolls being selected from the process consisting of rotary knife aperturing;

d. deforming said first fibrous web material by processing through said pair of rolls;

e. providing a second pair of rolls forming a nip through which said second fibrous web material can be processed, said pair of rolls being selected from the processes consisting of, ring rolling, SELF, micro-SELF, and rotary knife aperturing;

f. deforming said second fibrous web material by processing through said second pair of rolls; and

a. combining said first and second absorbent fibrous web materials with a non-fibrous-material to form said absorbent core;

wherein the first fibrous web material is not deformed by the second pair of rolls, wherein the second fibrous web material is not deformed by the first pair of rolls, wherein the rolls comprising rotary knife aperturing comprise teeth that are pointed at an end and sharpened to cut through the web, wherein the teeth have a length between 0.5 mm to 3 mm, a width between 0.3 mm to 1 mm, and a tooth aspect ratio of Tooth Length to Tooth Width of at least two.

2. The method of claim 1, wherein said first fibrous web material is selected from the group consisting of meltblown, spunbond, carded, wetlaid, and airlaid webs.

3. The method of claim 1, wherein said second fibrous web material is selected from the group consisting of meltblown, spunbond, carded, wetlaid and airlaid webs.

4. The method of claim 1, wherein both said first fibrous web material and said second fibrous web material are air laid webs.

5. The method of claim 1, wherein said combining step forms the first and second fibrous webs into a layered relationship.

6. The method of claim 5, wherein said combining is achieved by a method selected from the group consisting of:

adhesive bonding, thermal bonding, fiber entangling, latex bonding, and combinations thereof.

7. The method of claim 1, wherein said first or second fibrous webs comprise an airlaid web formed of discrete layers, each said layer comprising a different type or blend of fibers.

8. The method of claim 1, wherein one of said first or second fibrous webs comprises a blend of cellulosic fibers and bicomponent fibers.

9. The method of claim 1, wherein one of said first or second fibrous webs comprises a layer of cellulosic fibers and a layer of a nonwoven web.