CA2281975C - Sanitary napkin having an independently displaceable central core system - Google Patents

Abstract

A sanitary napkin is disclosed having an absorbent core comprising a central core segment and two side core segments. The sanitary napkin also includes a lifting member for displacing the central core segment relative to the side core segments.

Description

WO 93r17437 PCTNS95lOS090 i~
SAMTARY NAPKIN HAVING r~u'~t IIr'DEPENDENTLY
DISPLACEABLE CENTRAL CORE SEG~N?
FIELD OF THE INVENTION
The present invention relates generally to disposable absorbent articles such as sanitary napkins and more particularly, to a sanitary napkin having an absorbent core comprising distinct core segments, and a lifting member for providing independent displacement of at least one of the core segments relative to the other core segments ~CKGROCmtD OF THE >NVE'NTION
Absorbent articles such as sanitary napkins, parttilitters, and incontinence pads are designed to absorb and retain liquid and other discharges from the human body, and to prevent soiling of the body and clothing by such discharges. It is generally desirable to provide absorbent articles such as sanitary napkins which maintain contact with the body of the weuer when they are worn, and which conform as closely as possible to the body of the wearer. Such body conforming capability is belirved to increase the effectiveness of the sanitary napkin by reducing the possibility that menses will fraud around the perimeter of the sanitary napkin and soil the weeds body and/or clothing.
There have beat s numbs of recent efforts to provide sanitary napkins and other absorbent uncles with improved fit characteristic. Such recent efforts are described in U.S. Puent 4,950,264 issued August Z1, 1990 to Osbott~ U.S.
Patent 5,007,906 issued April 16, 1991 to Osborn; U.S. Psient 5,197.959 issued March 30, 1993 to BueU; tWp 92/075.5.
: and PCT International Publication Number WO
92/07535 publislud Msy 14, 1992 in the name of Visscha et al. In addition, the following commonly assigned and copending U.S. Patart Applications provide satutuy napians having internal shaping components and lifting members:
"Sanitary Napidu Having a Pleated Lining Memba," CA 2 ,17 9 , 4 8 5 filed Decetrner 13 .
1994 and CA 2.178,588 filed December 19, 1994.
These have also been efforu to provide a disposable absorbent articles having two or more absorbent portions or layers. The following documrnts describe disposable absorbent articles having multiple absorbent portions or layers:
Great WO 95~1'flSl PCrlLIS9510I090 i Britain Patent 23.103 issued October 28. 1915 to Mycroft; U.S. Patent 3,071.138 issued January 1. 1963 to Garcia: (l.S. Patent 3.653.382 issued April 4, 1972 to Easley et al.; U.S. Patent 3.954,107 issued May 4, 1976 to Chesky et al.:
C.'.S. Patent x,340,058 issued July 20, 1982 to Pierce: U.S. Patent 4,589,876 issued May 20.
1986 to Van Tilburg; U.S. Patent 4,973,325 issued November 27, 1990 to Shertod et al: U.S. Patent 4,988,344 issued January 29, 1991 to Reining et al.: and CA
Patent Application Serial No. 2.~ 097 , 336 filed Decetnbex 10, 1991.
While the sanitary napkins disclosed in thex references represent advancements in the art, the search for new and different ways of improving body contact has cornirwed.
It is espeaaily desirable that the sanitary napkin maintain contact with and conform to the body of the wearer under dyn:mic conditions (when the wearer walks, sits, etc.). For instance, when the sanitary napkin is worn. the sanitary napkin is subjected to lateral compression by the upper portions of the wearetas thighs. The forces applied by the wearer's thighs .generally tend to distort the shape of the sanitary napkin, roducing the size of the target the s:nitary napkin provides.
One sttanpt to control the e$ect of thex compressive forces is disclosed in UK Patent Application 2,168,612A, pubs June 25, 1986. The UK patent application discloses a sarrituy towel with a resilient inxrt positioned within the core or adjacent to s fact of the core that is intended to inlu'bit permanent distortion of the towel. The UK sppliation teaches that the insert resists lateral deformation of the sanituy towel, but does not teach or disclox s s:r>atary napkin having body conforming Propatia.
It is also dG9rabie to provide a sanitary napkin which conforrai to the weuer's body while maintaining the comfort of the wearer. Accordingly, s desirable sanitary napkin should mairuain contact with the waa~'s body, Yet be capable of repented eissoic deflection to allow the watrer to comfortably assume diffaatt positions and to perform diffa~aa activities.
It is therefore an object of an aspect of this invention to provide an absorbent article, such as a sanitary napkin, which intercepts menxs by cauforming to the shape of the female urogenital region.
It is another object of an aspect of the present invention to provide an absorbent article having a bi~levd core and a bi-level body facing ur~~.
Another object of an aspect of the present invention is to provide a sanitary napkin having WO 951Z7~37 PCTIU593/01090 ._- _ f 5 separate core segmenu.

Yet another object of an aspect of the present invention is to provide a sanitary napkin having a lifting member for displacing a central absorbent core segment relative to side absorbent core segmenu.
These and other objects of aspects of the present invention will be more readily' apparent 10 when considered in reference to the following description and when taken in conjunction with the accompanying drawings.
The present invention is an absorbent article, such as a sanitary napkin having a 15 longitudinal centerline, a lateral centerline, and first and second longitudinally extending sides joining first and second laterally extending ends. The sanitary napkin of the present invention has a liquid pervious topsheet having s body facing surface, a liquid impervious backsheet joined to the topsheet, an absorbent core dispoxd intermediate the topsheet and the backsheet, acrd a lifting member disposed 20 intermediate a portion of the absorbent core and the backslteet.
The absorbetrt core comprises a central core segment having a later! width less than the total lateral width of the absorbent material in the sanitary napkin. The central core segment attends along the long;urdinal catterline of the sanitary napkin.
The absorbent core also includes s first longitudinally extending side core segment 25 disposed imermediate the longitudinal centerline acrd the first longitudinally extending side of the sanitary napkin, and a second longitudinally attending side core xgment disposed intermediate the longitudinal centerline and the second longitudinally extending side of the s:nitary napkin. The first and second side core xgmenu are prcfaably xparate from the central core xgnratt.
30 The lining member is disposed intermediate the badcsheet and the central core segment for providing Z-direction displacement of the central core segment relative to the first and sxond side core xgmenu. The lifting member is preferably a longitudinally actarding lifting member having s plurality of plesu along iu length.
The lifting member can comprise s pleated first dement and a second element joined 35 to the first danent at spaced apart locations along the length of the first element.
wherein elastic contraction of the second dement relative to the first element gathers the fires dement to form pleats in the first dement.
In one embodiment the saruwy napkcin further comprises a wicking member.
which ii preferably a tissue papa web comprising cellulosic fibers. The wicking 40 mamba conveys fluid intermediate the central core xgment and the first and second r side core segments. The wicking member can have a central portion disposed intermediate the central core segment and the lifting member, a first side portion disposed intermediate the backsheet and the first side core segment, and a second side portion disposed intermediate the backsheet and the second side core segment.
In accordance with one embodiment of the present invention, a mold comprises:
a mold top surface;
a deposition cavity formed in the mold top surface, the deposition cavity bounded by a perimeter sidewall and a foraminous bottom wall; and as least one partition dividing the deposition cavity into cavity segments.
In accordance with another embodiment of the present invention, a method comprises:
providing a source of vacuum;
providing a mold, the mold comprising:
a mold top surface;
a deposition cavity formed in the mold top surface, the deposition cavity bounded by a perimeter sidewall and a foraminous bottom wall, the foraminous bottom wall in flow communication with the source of vacuum; and at least one partition dividing the deposition cavity into segments, each partition providing an interconnection between adjacent cavity segments;
depositing material into each of the cavity segments to form interconnected core segments; and separating the interconnected core segments subsequent to forming the interconnected core segments.
~~ DESCR1~I ION OF T~ DEiAWIIV(ab ' Fgure i is a top plan view of s sanitar~r napkin of the present invention with portions of the sanitary napkin shown ant away to reveal separate core Fgure 2 is s section view taken along line 2-2 of Fgure 1 which show: the sanitary napkin of the present inva>aon in a compressed caet5guruion.
Fgure 3 is a section vicar of the s~inry nspkin of Fgure 2 shorn in an attended configuration.
figure 4 is s section view tskm along line 4-4 of Fgure 1 which shows a sanituy napkin of the presatt idva>tion is an oc~ded con5guration, and it 4a s lung member with pleas of g~aal~r ~m Z-direaiot, hdght, the pleats octa~di~ along the bngiardind centtr4rre of the saautary naplan.
Flgure 5 is as exploded view of a :amnry napl~ accor~diag ~ w one anbodime~ of the praaa inventioa.
Fgurre 6 is a aeon view smaiiar to that of Figure 3, showing a laminae of absorbent gelling au~tcial sandwiched between two tissue papa webs, tha ab~rbrat gd~g mataid and tiara papQ webs poswoned irrtarmediats a Wing a~nba and a camel core segmara.
Figure 7 a s seatiou view ~ to that of F~ure 3, showing a I~inate of absofbent maaid saadarichad ba~roen two tissue pspa webs, the abaotbent gel~g ~taial and tiaue paper webs positioned atrtetmediate a li~g tnanbc and tire bedn6ea.
Fgute E is a xaion view sitnilu to that of Figure 4 showing s central core s~m~ comprising a low dauity acquisitive region having lonaliy extending apilVry chaond >;bas.
Fgun 9 is a section view :amiLr to that of F~urre 4 showing an ahanue embodinratt of a coal core xgment comprising a low dauit5r ~ m&~ ~B I~Y Y channel Fgure 10 is a xhanatic side elevation view of an apparan~s for forming the lifting m~nba of the ptesa~t invaeion by di$aast>avy dong~g two or w0 95/Z7457 ~ PCTIUS95I04090 _-r. ~_ _ s x f 5 more elements and intermittently joining the differentially elongated elements along their lengths.
Figure 11 A is a schematic side elevation view of another apparatus for forming the lifting member of the present invention.
Figure 11 B is a top view of the folding board of Figure 11 A.
10 Figure 12 is a top view of as airfelt deposition mold having a pair of parallel partitions extending in the machine direction and dividing the mold cavity into three mold cavity segments, the mold suitable for forming central and side core segmenu on an airfelt laydown drum.
Figure 13 is a side view of one of the partitions of Figure 12.

DETAILED DESCRIPTION OF THE INVENTION
Figures 1-4 illustrate a sanitary napkin 20 according to one embodiment of the disposable absorbent article of the present invention. As used herein, the term "absorbent article" refers to articles which absorb and contain body exudates.
More ZO specifically, the term is intended to include, but not be limited to, sanitary napkins, pantiliners, and incontinence pads (articla worn in the crotch region of a garment).
The term "disposable" refers to articles which are intended to be discarded after a single use rather than laundered or otherwise restored or reused.
The sanitary napkin 20 has a perimeter having first and second longitudinally 25 extending sides 28A and 288 joining first and second laterally extending ends 30A
and 30B. The sanitary napkin also has a longitudinal centerline 29 and a lateral centerline 31. As used herein the term "longitudinal" refers to a line, axis, or direction gerta~ally aligned with the vertical plane which bisects the standing wearer into left and right body halves. The term "lateral" refers to a line, axis, or direction 30 generally pa~pmdicular to the longitudinal direction and tying within the plane of the sanitary napkin 20. The sanitary napkin 20 is typically longer in the longitudinal direction than in the lateral direction.

WO 93r1'7137 PLTIUS93/Od09a 5 The "Z" direction refers to a line, axis, or direction which is perpendicular to the plane of the sanitary napkin (i.e., perpendicular to both the longitudinal axis 29 and the lateral axis 31 when the sanitary napkin is supported in a generally flat configuration). T'he Z direction is illustrated in Figure 3.
The sanitary napkin 20 according to the present invention comprises a liquid 10 pervious topshett 40 having a body facing surface 42; a liquid impervious backsheet 50 having a garment facing surface 52; and as absorbent core 60 disposed intermediate the topsheet 40 and the backsheet 50.
The absorbent core 60 comprises a three piece construction which includes a central core segment 62 extending along the longitudinal centerline 29, a first 15 longitudinally extending side core segment 64, and a second longitudinally extending side core segment 66. The first and second core side segments 64 and 66 are disposed intermediate the longitudinal centerline 29 and the first and second longitudinally extending sides 28A and 28B of the sanitary napkin 20, respectively.
The absorbent core 60 has a longitudinal ltngth L (Figtue 4) measured along the 20 longitudinal centerline 29 which is typically greater than the absorbent core's lateral width W (Figure 2) mes~rred along the lateral centerline 31.
The sanitary napkin 20 according to the presatt invention further comprises a lifting member 100 disposed intermediate the backsheet 50 and the central core segment 62. The lifting member 100 can be disposed laterally intermediate the first 25 and second core side segments 64 and 66. The lining member 100 provides Z-direction elastic displacement of the central core segment 62 relative to the first and second side core segments 64 and 66 and the backsheet 50.
By "Z-direction elastic displacement" of the central core segment 62 relative to the backshxt 50 and the side core segments 64,66, it is meant that the central core 30 segmait 62 can be displaced relative to the backsheet 50 and the side core segments 64,66 in the Z-dire~on fi-om a first, extended con5guration, wherein the sanitary napkin 20 has a Z-direction caliper Z 1 shown in Figures 3 and 4, to a second compressed configuration. having a caliper Z2 shown in Figure 2 (such as by the compressive Z-diration load 200), and that the lifting member 100 will restore the 35 sanitary napkin 20 to have a Z-direction caliper which is at least about 70 percent of the Z-direction caliper Z 1 upon release of the compressive loading, when the sanitary napkin is dry and has not been loaded with body exudates. The elastic displacement of the topsheet 22 relative to the backsheet 24 can be expressed by the difference Z 1 - Z2.
40 The Z-direction calipers Z 1 and Z2, and the corresponding Z-direction WO 95IZ'fi57 PLTIU595/04090 compressive loading are measured using a suitable tensile testing machine.
such as an Instron Model 450? tensile testing machine manufactured by the Instron Engineering Corporation of Canton, Mass.
By lifting the central core segment 62 relative to the side can segments 64.
66.
the lifting member 100 maintains contact of a portion of the topsheet 40 overlying the central core segment 62 and extending along the longitudinal centerline 29 with the wearer's body. The lifting member 100 convady shapes the body facing surface 42 of the topsheet 40 to conform to the wearer's body, particularly in the labia.
perineum, andlor gluteal groove areas. The lifting member 100 also biases the central core segment 6Z into engagement with the portion of the topsheet 40 along the longitudinal centerline 29 to tnhance acquisition of body fluids by the central core segment 62 from the portion of the topsheet 40 aetending along the longitudinal centerline 29.
The central core segment 62 prefaabiy has s lateral width W 1 (Fgure 3 ) malong the lateral centerline 31 which is less than the tataal width W of the absorbert core 60. A lateral width W 1 which is less than the lateral width W
reduces the weight of absorbent material displaced by the lifting member 100. Reducing the weight of absorbtnt material displaced by the lining member 100 reduces the required stress of the lining member 100, and thereby provides a more comfortable fit for the weans. The side care segments 64 and 66 preferably have lateral widths W2 and W3 which are less than the width W of the absorbent core 60. The side core segrnatts 64 and 66 can be luerally spaced apart s distance greater than the width Wl so that the ants core segment 62 is positioned laterally intermediate the side core segmeau 64 and 66 when the sanitary nsplon 20 is compressed as shown in Fgtue 2.
The lifting member 100 displaces the certral core segment 62 to extend above the plane of the side core segments 64 and 66. The lining member 100 thereby provides a bi-feud core 60 and a bi-feud body faring ssu~Ce 42 of the topsheet.
Such a bi-feud core 60 and bi-Ievd body fi~cing sut'fuxx 42 improves body fit by providing enhanced contact with the labia, prcinautL and gluteal groove areas of the body. In addition, s Istaal width W 1 which is less than the lateral width W
promotes convex shaping of the body facing surface 42 of the topsheet 40 along the longiwdina! centerline 29, and thereby enhances fit in the labia, perineum.
andlor WO 931Z'7I5~ PCTIUS93/Od090 _ _ 5 gluteal groove areas of the body.
The central core segment 62 is preferably separate from the first and second core side segments 64 and 66. The central core segment should be separate from the first and second core segmenu 64 and 66 so that the lifting member 100 can displace the central core segment 62 independently of the side core segments 64 and 66.
By 10 the term "separate" it is meant that the central core segment 62 is not an extension of.
nor directly joined or directly connected to either of the first and second core side segments 64 and 66 by adhesive or other fastening means. Of course, the central core segment 62 can be separate from the first and second side core segments 64 and 66 and yet be indirectly joined to the side core segments 64 and 66 by one or more 15 other elemenu of the sanitary napkin 20. For instance, the topsheet 40 can be directly joined to each of the core segmectts 62, 64, and 66, and thereby indirectly join the core segmenu 62, 64 and 66.
Referring to Figures 2 and 3, the sanitary napkin 20 according to the present invention can have a wicking member 70 for conveying body fluids from the central ZO core segment 62 to the first and second side core segmenu 64 and 66. The wicking member 70 can also provide lateral support for the lifting member 100 when the sanitary napkin is in the extended position shown in l: figures 3 and 4. The wicking member 70 can comprise s web of cdlulosic fibers, such as a web of tissue paper.
The wicking member 70 can have a first longitudinally extending side portion 74, a 25 second longitudinally extending side portion 76, arid a longitudinally extending central portion 72 extending laterally intermediate the first and second side portions 74 and 76. The first side portion 74 is disposed intermediate the first side core segmtttt portion 64 and the backsheet 50. The second side portion 76 is disposed intermediate the second side core segment 66 and the backsheet S0. The central 30 portion 72 is disposed intermediate the central core segrnart 62 and the lifting member 100. The wicking member 70 can have a pair of longitudinally extending folds 71 for accommodating extension of the lifting member 100 in the Z-direction.
The sanitary napkin 20 according to the present imrention can also have a support member 80. The support member 80 has a lateral width greater than the 35 lateral width of the lifting member 100 and distributes loads from the lifting member 100 to the backsheet 50. The support member 80 also stiffens the swcture of the sanitary napkin 20 undatying the lifting member 100. The support member 80 thereby helps to ensure that the lifting member 100 displaces the central core segment 62 upward relative to the side care segments 64 and 66 and the backsheet 50.
40 The support member 80 can attend laterally intermediate the first and second WO 93lZ7437 PCTNS93IOd090 _....~_ _ x f 5 side core segments 64 and 66, and can comprise a web of cellulosic fibers, such as a web of tissue paper. The support member 80 can have a first longitudinally extending side portion 84, a second longitudinally extending side portion 86, and a longitudinally extending central portion 82 extending laterally intermediate the first and second side portions 84 and 86. The central portion 82 is joined to the lining 10 member 100 and at least the first and second side portions are joined to the backsheet 50. The first side portion 84 is disposed intermediate the firn side core segment 64 and the backsheet 50. The second side portion 86 is disposed intermediate the second side core segment 66 and the backshett 50. The central portion 82 is disposed intermediate the lifting member 100 and the backsheet 50. The wicking 15 member 70 and the support member 80 preferably have a lateral width less than the width W of the absorbent core 60 to prevent wicking of body exudates to the longitudinally extending sides 28A and 28B of the sanitary napkin 20. In the embodiment shown in figures 1 through 4 the central portion 72 of the wicking member 70 is joined to the lifting member 100, and the side portions 74 and 76 of the 20 wicking member are joined to the side portions 84 and 86, respectively, of the support member 80.
Examining the components of the sanitary napkin 20 in more detail, the topsheet 40 is the componatt . of the sanitary napkin 20 oriented towards and contacting the body of the wearer for receiving body exudates. The topsheet 40 is 25 flexible, soft feeling, non-irritating to the wearer's skin, and is liquid pervious. As used herein, the term fle~able refer to materials which are compliam and readily conform to the shape of the body or respond by easily deforming in the presence of actaval forces. Preferably, the topsheet 40 is not noisy to provide discretion to the wearer.
30 The topshed 40 should be clean in appearance and can be somewhat opaque to hide the discharges collected in the core 60. The topsheet 40 preferably has a pair of laterally spaced apart and longitudinally extending folds 41. The folds 41 in the topsheet 40 accommodate the Z-direction displacement of the central core segment 62. The folds 41 also permit independent Z-direction displacement of the central 35 core segment 62 relative to the core segments 64 and 66 when all three core segments are joined to the topsheet 40.
The topsheet 40 is preferably joined to the backsheet along the longitudinal sides 28A and 28B and along one or both of the lateral ends 30A and 30B. The topsheet 40 can be joined to the backsheei 50 to provide Z-direction decoupling of 40 the topsheet 40 from the backsheet 50, as described in U.S. Patent 5,007,906 issued r.

.~~ -- _ I 0 s' f April 16, 1991 to Osborn et al. The topsheet 40 can be joined to the backsheet 50 by any suitable method, including but not limited to adhesive bonding, ultrasonic bonding, or thermal bonding.
The topsheet 40 should exhibit good strike-through and rower characteristics, permitting bodily discharges .to rapidly penetrate the topsheet 40 to the core 60. A
suitable topsheet 40 may be made from a wide range of materials, such as woven and nonwoven materials: polymeric materials such as apa~du~ formed thermoplastic films. apertured plastic films; and hydroformed thermoplastic films; porous foams;
reticulated foams: reticulated thermoplastic films: and thermoplastic scrims.
Suitable woven and nonwoven materials can be comprised of nature! fibers (e.g., wood or IS cotton fiben), synthetic fibers (e.g., polymeric fibers such as polyester, polypropylene, or polyethylene fibers) or combinations of natural and synthetic fibers.
The topsheet 40 has a plurality of aperarres to permit liquids deposited thereon to pass through to the core 60. The topsheet 40 can comprise an apa~aued formed polyolefinic film having about 5 to about 60 percem open arcs and a thickness of about o.01 to about 0.05 millimeters. Referring to Figure 5, the topsheet 4o can comprix a primary topsheet layer 44 joined to a secondary topsheet layer 46.
The primary topsheet layer 44 can comprix an apawrdd formed polyolefinic film made in accordance with one of the following U.S. Patents: U.S. Patent 3,929,135 issued December 30, 1975 to son; U.S. Patent 4,324,246 issued April 13, 1982 to MuUane; U.S. Pat. No. 4,342;314 issued Aug. 3, 1982 to Radd et al.: U.S. Pat.
No.
4,463,045 issued July 31, 1984 to Ahr et al.; and U.S. Patent 5,006,394 issued April 9, 1991 to Hairdr 'The secondary topsheet layer 46 can comprix a nonwoven web of natural or synthetic 5bas. Suitable nomvovens from which the seconduy topshea layer 46 can be formed indude s nonwoven web of spunbond polypropylene fibers designated P-hsvirtg a basis weight of about 18 grams per squue yard and available firom the F~tba'web Corporation of SimpsonviUe, South Carolina undo the tradmune CEt.ESTRA.* Another suitable nonwoven from which the secondary topsheet layer 46 can be formed is an airthrough bonded fabric having s basis weight of about B~s Pa ~ meter formed of bicomponent fiber:, the 5bers having a polyethylene sheath and a polypropylene or polyester core. Such an airthrough bonded fabric is available from the Havix Company (formerly Fukumura) of Ijra~
Mun Japan as S2416 airthrough bonded fabric.
The primary and sewn dary topsheet layers 44 and 46 are preferably joined * = Trade-mark WO 95117437 Pl?/US95/04090 i~ (1 5 together by a plurality of discrete bonds 45 (Figure 5). The bonds 45 are preferably formed using the mechanical bonding method disclosed in U. S. Patent 4.9 t 9, 7; 8 issued April 24. 1990 to Ball et al., which patent is incorporate herein by reference.
Alternatively, the layers 44 and 46 can be joined using other methods, including but not limited to adhesive bonding, ultrasonic bonding, and thermal bonding.
10 The backsheet 50 may be any flexible liquid impervious material. such as a polyolefinic 51m. The backsheet 50 prevents dixharges cotleaed by the sanitary napkin 20 5rom soiling the wearer or the wearer's clothing. The backsheet 50 can be a low density polyethylene film about 0.01 to about D.OS millimeters in thickness, and preferably about 0.025 millimeters ( 1.0 mil). Suitable polyethylene films from which 15 the backsheet 24 can be formed are sold by the Ethyl Corp., Visqueen Division. as Model x~39385 and by the Clopay Corp. of Cincinnati, Ohio as SOFLEXX 1401.
The backsheet 50 can have a surface area greater than or equal to that of tha topsheet 40 and the absorbatt core 60, and preferably peripherally circumscribes the topsheet 40 arid the core 60. The backsheet 40 may compcix flaps (not shown) 20 extending outwardly from each longitudinally side 28A and 28B. The flaps may be made in accordance with the teachings ofU.S. Patent Nos. 4,589,876 issued May 20.
1986 to Van Tilburg and 4,687,478 issued August 18, 1987 to Van T'~burg, The backsheet 50 and the flaps may be unitary and coextensive. Alternatively, the flaps can be separate components joined to the 25 backsheet.
The garmatt facing atrface 52 of the backsheet 50 may comprise an attachment means 56 (Fgure 5) for xcuring the unitary napkin 20 to the undergarmesu of the weans. Prefand attachment means 56 include mechanical fattaters, or more prefaabty, pressure sa>sitive adhesive. The pressure sensitive 30 adhesive may be spplied to the garment facing surface 52 in one or more strips or patches. A suitable adhesive is Century Adhesive A-305-N manufacarred by Century Adluaives Core. of Columbus Ohio. A strip of silicone coated rdease paper 57 can cover the adhesive to prevent soiling of the adhesive prior to use. In one embodiment taro paraDd strips of pressure adhesive can be applied to the garment 35 facing stuface 52, each strip of adhesive underlying one of the side core segments 64, 66.
The absorbent core 60 receives and contains body exudates, particularly menses. Suitable materials from which the core segments 62, 64 and 66 include a wide variety of liquid-absorbent materials such as comminuted cellulosic wood pulp 40 8bets, which is generally referred to as airfelt. Examples of other suitable materials WO 93n'1i37 PCT/US95IOi090 .
;_ _ l2 5 include but are not limited to creped cellulose wadding: meltblown polymers, chemically stiffened, modified, or cross-linked cellulosic fibers: absorbent foams:
layers of tissue paper: and absorbent gelling materials.
In the embodiment shown in Figures 1-7 each of the absorbent core segments 62, 64, and 66 comprises an airlaid airfelt pad of cellulose fibers, which fibers are 10 available from the Foley, Florida plant of the Buckeye Cellulose Company of Memphis, Tennessee. The core segments 62, 64 and 66 can be formed exclusively of cellulose W O 93127.137 1. 13 5 fibers, or alternatively, can include other materials such as absorbent gelling materials in addition to cellulose fibers.
Each of the core segmenu 62, 64, and 66 can have a length of about .00 millimeters. The widths W 1, W2, and W3 (Figure 3 ) can each be about '' S
millimeters. Each of the core segmenu 62, 64, and 66 can have a thickness t (Figure 10 4) of about 4.9 millimeters in the abxnce of cani3ning pressure. The combined weight of the core segments 62, 64, and 66 can be about 4.1 grams, with each core segment weighing about 1.37 grams.
The core segmenu can be airlaid separately, or formed as a unitary pad, and then separated into individual core xgmems.
15 ' U.S. patent 4,388,056 issued June 14, 1983 to Lee et al.: U.S. Patent 4.551.191 issued November 1985 to Kock et al.: U.S. Pateni 4,592,708 issued June 3, 1986 to Feint et al.; and U.S. Patents 4,765,780 and 4.908.175 issued August 23, 1988 and March 13, 1990 respectively to Angstadt et 20 al.
Absorbent cores can be formed in discrete cavities on a laydown drum, as disclosed in U.S. Patent 4,859,388 issued August 22, 1989 to Peterson et al., . . Figure 12 show: an airfelt deposition mold 500 suitable for formingthe core segments 62, 64, and 66 on an airfelt laydown 25 drum. A phrralmr of the molds 500 are mounted on the cirarmference of the laydown drurr~ which rotates in s machine direction (IVm) indicated in Figure 12.
Each mold 500 has a top ararate sur<ace $OZ. Together, the arcuate top surfaces 502 of the molds 500 form the perimeter of the laydown dmm. The machine dir~ctioa corresponds to the. longitudinal direction on the sanitary napkin 20. The 30 cross machine direction (CD) is generally parallel to the axis of rotuion of the laydown drum, and corresponds to the lateral direction on the unitary napkin 20.
The mold 500 comprises a deposition cavity 510 formed in the arcuste cop surface 502. The deposition avity 510 is bounded by a perimeter sidewall 520 and a foramittous bottom wall 530. The foraminous bottom wall 530 can compcix a 35 screen. AirBow through the foraminous bottom wall 530 is created by a vacuum within the lsydown drum. The airflow through the foraminous bottom wall 530 carries cellufosic fiber: into the cavity 510 for deposition on the foraminous bottom wall 530.
According to the present imiention. the cores segments 62, 64, and 66 can be 40 formed to be interconnected in a mold 500 having two generally parallel partitions PCT/US95l04090 _-t.;= _ l4 5 550. Referring to Figure I3, each partition 550 has an arcuate top edge 552 concentric with an arcuate bottom edge 554, and a pair of beveled side edges 556.
The edges 552, 554, and 556 extend between oppositely facing sidewalls 558 The beveled side edges 556 engage grooves 522 in the perimeter sidewall 520 of the deposition cavity 510. The foraminous bottom wall 530 supports the bottom edge 10 554 of each partition 550, and prevents the partition 550 5rom falling out of the grooves 522. The top arcuate edge 552 of each partition 550 is flush with the top arcuate surface 502 of the mold 500 when the partition 550 is supported in the grooves 522. .
The partitions 550 extend in the machine direction and divide the deposition 15 cavity 510 into three cavity xgments S I OA, 51 OB, and S l OC. Fibers deposited in the cavity segments 5 IOA, B, and C form the core xgmenu 62, 64, and 66, respectively.
Each partition 550 can have one or more passageways along its length for interwnnecting adjacent cavity segments S I OAB and S I OA/C. Referring to Figures 12 and 13, the passageways can comprix slots 553 in the top edge 552 which extend 20 in the cross-machine direction through the thickness of the partition 550.
Fibers deposited in the slots 553 as the cavity segments S l0A-C are filled form a bridge between adjacent cores segments 62/64, and 62/66. The slots 553 thereby provide structural Interconnection between the core segments 62/64 and 62/66 as fibers are deposited in the cavity segrnettts. In alternative embodiments the partitions 550 can 25 extend in the cross-machine direction, or in both the machine and cross-machine directions.
For the core segments 62, 64, and 66 described above, the partitions 550 can be formed froth stainless steel sheet stock having a thicbtess 562 of about 1.6 millimeter, and have a height 564 of about 9.5 millimeter. The arcvate top edge 552 30 can be formed on a radius of about 409 millimeters and have a cord length 566 of about 203 millimeter. The arcuue bottom edge 554 an be formed on a radius of about 399 millimeters and have a cord length 568 of about 205 millimeters. The slots 553 can have a height 572 of about 3.2 millimeters and a width 574 of about 6.3 millimeters. The slots 553 can be spaced apart on the top cdge 552 by an angle 35 of about 8 degrees. The side edges 556 can be beveled at an angle 578 of about 5 degrees.
The mold 500 having partitions 550 provides the advatrtage that the core segments 62, 64, 66 can be formed and conveyed as a unit, and subsequently separated at any desired point prior to, or aRer, joining the core xgments 62, 64, 66 40 to other components of the sanitary napkin 20. The mold 500 having partitions 550 w0 95127457 PCT1US95I04090 _ x P
IS
5 can also be used to form core segments 62. 64, and 66 from different materials, or having different density or basis weight characteristics. Different core se~mert.~, can be formed by directing different materials or different quantities of the same material into the cavity segments 5 l0A-C, or by varying the vacuum within the laydown drum to vary the air drawn through the portion of the foraminous bottom surface 530 10 subjacent each of the cavity segments 5 l0A-C. Alternatively, the absorbent core 60 can be formed as a single airfelt pad, and then cut longitudinally to provide the individual core segments 62, 64, and 66. However, such cutting can res:~lt in undesirable densification of the cut edges of the core xgments.
Referring to Figures 1-4, the lifting member 100 displaces the central core 15 segment 62 relative to the backsheet 50 and the side core xgments 64 and 66. In one embodiment the lifting member 100 comprises a plurality of pleats 115. The pleats 115 provide Z-direction elastic displacement of the central core segment 6~
and a portion of the topsheet 40 along the longitudinal centerline 29 relative to the side core xgments 64,66 and the backsheei 50. The lifting member 100 thereby 20 provides a bi-level con 60 and a bi-level body facing surface 42 of the topsheet. The pleau 115 also preferably comrexly shape a portion of the body facing surface 42 of the topsheet 40 along the longitudinal centerline 29, as shown in Figure 3.
The lifting member 100 thereby maintains contact of the portion of the topsheet 40 along the longitudinal centerline 29 with the wearer's body, and shapes the topsheet 40 to 25 conform to the wearer's body, particularly in the labia, perineum, and/or gluteal groove areas.
The lifting member 100 cart comprix a longitudinally extending first pleated element 110 having a plurafrty of pleats 115 along iu length. Each pleat 115 has a Z-direction height H1 figure 4) when the sanitary napkin 20 is in the extended position 30 shown in Figures 3 and 4. The lifting member 100 preferably also includes a longitudinally extending second element 120 disposed intermediate the first element I 10 and the central core xgment 62. The lifting member 100 can also include a longitudinally extending third element 130 disposed intermediate the first element 110 and the backsheet 50. In the embodiment shown in Figtua 2-4, the second 35 element 120 is positioned between the first element 110 and the first wicking member 70, and the third element 130 is positioned between the first element 110 and the support member 80.
The second and third elements 120 and 130 can be joined to the first element 110 at spaced apart locations along their respective lengths. The pleats 1 l5 extend 40 between the xcond and third elemenu 120, 130. The second and third elements w0 93IZ7437 PCTN593/04090 5 and 130 bridge adjacent pleats 1 I S and stabilize the pleats 115 to help prevent lateral collapse (such as by buckling) of the pleau 115 when the sanitary napkin is in the extended position shown in Figure 3.
The second eleme ' 20 preferably comprises an elastic element. Elastic contraction of the elastic second element 120 gathers the first element l 10 about fold 10 lines generally parallel to the lateral centerline 31 to form the pleau 115 along the length of the first element 110. The second element 120 is also preferably elastic to provide a force for maintaining the Z-direction height of the pleau 115, and for restoring the Z-direction height of the pleau 115 when the pleau 115 are compressed by a Z-direction load such as the compressive load 200 shown in Figure 2. The 15 pleau 115 are compressed by the load 200, such as when the wearer is sitting, to provide for the comfort of the wearer. When the compressive load 200 is removed (e.g., when the wears stands up), contraction of the elastic second element restores the Z-direction height of the pleau 115 and thereby maintains contact of the topsheet 40 with the wearer's body.
20 The third element 130 can also comprise as elastic third element 130. In one embodiment both of the second and third demmu 120 and 130 are elastic elemenu, and elastic contraction of one or both of the elastic second and third elemenu 120, 130 gather the first elastic dement 110 to form the pleau 115. In yet another embodiment the first elemtnt 110 can also comprise an elastic dement.
25 The term "elastic element" refers to a component which has a free length and which can be strained by a tensile force to have a percentage of elongation of at least 35 percent (elongated length greater than or equal to 1.35 x free length), and wherein upon release of the tensile force the component contracts to within 5 percent of its free length within tm seconds.
30 In one anbodimertt, the ability of the .lifting member 100 to restore the Z-direction caliper of the sanitaryr napkin 20 is relatively unaffected by wetting of the lifting member 100. The sifting member 100 can have a wet caliper reduction which is no more than about 20 percent greater than its dry caliper reduction, and a wet caliper reduction of no more than about fight percent. The wet caliper reduction and 35 dry caliper reduction for the lifting member 100 are measured using the following procedure repeated for four lining member samples.
The lifting member 100 is adhesively attached to a sheet of polyethylene film having a thickness of about 1.0 mil. The lifting member 100 and polyethylene film are supported on the horizontal surface of an analytical balance, or other suitable 40 scale. The Z-direction caliper of the lifting member 100 above the polyethylene film _ t~

5 is measured using a suitable displacement measuring system. A suitable displacement measuring system is an ONO-SOKKI DG 3610 Digital Gauge and an ONO-SOKKI
GS-503 Linear Gauge Sensor available from the ONO-SOKKI Corporation of Japan.
The Z-direction caliper of the lining member 100 is measured at various 2-direction load levels applied to the lifting member 100 through a circular load application foot 10 having a diameter of 0.95 inch. The toad application foot is connected to the linear gauge sensor.
The lifting member 100 and polyethylene film are placed on the balance, and the balance is fared out to have a zero reading. The initial dry Z-direction caliper of the lifting member 100 is measured with the load application foot just touching the 15 lifting member 100, so that the balance indicates a reading of about zero.
The Z-direction load on the lining member 100 is increased to 32.1 grams in about 5 equal increments, so that the balance indicates a weight of 32.1 grams. The load is then removed, and the unloaded dry Z-direction caliper of the lifting member 100 is recorded with the load appGcat:~n foot just touching the lining member 100, so that 20 the balance indicates a reading of about zero. For each sample, the difference between the initial dry Z-direction caliper and the unloaded dry Z-direction caliper is divided by the initial dry Z-direction caliper to obtain the percentage change in dry caliper of the sample. The dry caliper reduction is the average of the percentage change in dry caliper for the four lifting member samples.
25 Each lifting member (and its associated polyethylene sheet) is completely submerged in distilled water for 10 seconds, and then aDowed to drain vertically for 10 seconds. The lifting member 100 and polyethylene sheet are then supported on the horizontal s<uface of the analytical balance, and the balanced fared out to indicate a reading of zero. The initial wet Z-direction caliper of the lifting member 100 is 30 measured with the load application foot just touching the lifting member 100, so that the balance indicates a reading of about zero. The Z-direction load on the lifting member 100 is then increased to 32.1 grams in about 5 equal increments. The load is then removed and the unloaded wet Z-direction caliper of the lifting member 100 is recorded with the load application foot just touching the lifting member 100, so that 35 the balance indicates a reading of about zero. For each sample, the difference between the initial wet Z-direction caliper and the unloaded wet Z-direction caliper is divided by the initial wet Z-direction caliper to obtain the percentage change in the wet caliper of the sample. The wet caliper reduction of the lifting member 100 is the average of the percentage change in wet caliper for the four lifting member samples.
40 In one embodiment, the lifting member 100 is nonabsorbent. By WO 931=7457 PCTN595IW090 _~ l8 r 5 "nonabsorbent" it is meant that the lining member 100 has an absorbency capacity of less than 100 percent. The absorbenry capacity is the ratio of the weight of the water absorbed by a dry sample to the dry sample weight. A nonabsorbent lifting member 100 is believed to have the advantage that its stiffness and/or its ability to displace the central core segment 62 upward are relatively unaffected by body fluids entering the 10 absorbent article 20, as compared to a lining member which is absorbent.
The absorbency capscity of the lifting member is measured by first weighing the lifting member 100 to obtain its dry weight, and then completely submerging the lifring member 100 in distilled water for 10 seconds. After 10 seconds the tilling member 100 is removed from the wiser. The lifting member is then allowed to drain 15 vertically for 10 seconds. Wiser ushering to the s<rrfaue of the lining member is then removed by blotting the lining member beswsat two pieces of filter paper for t seconds. The lifting member 100 is blotted by placing a first piece of 5lter paper on ~
dry horizontal surface, placing the lifl~tg member on the first piece of filter papa.
placing a second piece of filter papa on top of the tilling member to cover the lining 20 member, and placing a piece of 0.25 inch thick Plexiglas weighing 0.26 pound on cop of the second piece of filter papa to cover the portion of the second piece of filter Paper overlying the lifting manta. A suitable filter papa for blotting the lifting member 100 is filtrarion papa having s relatively smooth surface, s particle retention size of greua than about 20-25 micron>esas, and a Hazbag filtruion speed of 25 about 37 seconds, where the filtration speed is the time for 100 ml of prefiltered water to pass through a 10.0 square centimeter piece of fiber paper with a constant head pre~re of 10 cattimeters of water. A suitable filtration papa is Whuman*4 filtration papa tnanufacuired by Whaa~nan. Ltd. of England and available from the Ftsher Scientific Company of Pittsburgh, Pa. After blotting the tilling member 30 for 10 seconds, the li$ing member 100 is immediately weighed to obtain the wet sample weight. ?lu dry wdght is subtracted firom the wa wagM to yield the grams of water absorbed by the dry sample. The pacauage absorbenry capacity is obvit>ed by dividing the grams of wiser absottied by the dry sample weight, and multiplying the quotient by 100.
35 In one anbod>mem the lifting member 100, and particularly the pleau 115, is hydrophobic. A sur6ce is hydrophobic if the cotuact angle betweea a liquid and the surfi<ce is grates than 90 degrees. The American Chemical Society Publication "Contact Angle, Wettability, and Adhesion," edited by Robot F. Gouid and copyrighted in 1964 .
40 .
* = Trade-mark WO 93r17137 PCTIUS93I0~1090 _,~..r _ l9 sw 5 In one embodimem the lifting member 100 extends along the longitudinal centerline 29 of the sanitary napkin 20, and can have a longitudinal lenr_tth which is approximately equal to the length L of the central core segment 6'_. The lifting member can have a lateral width C (Figure 1 ), corresponding to the width of the second and third members 120 and 130, which is less than the lateral width W 1 of the 10 central core segment 60. Without being limited by theory, a relatively large width C
provides lateral stability of the lifting member 100, and a relatively small width C
enhanca 5t of the raised portions of the topsheet and core with the labia, perineum.
and gluten! groove areas of the body.
The first danent 110 can be formed from a number of suitable materials.
15 including but not limited to woven and norrwoven sheet rtraterial, plastic films. arid natural or synthetic rubber strands. One suitable material from which the first element 110 cart be formed is a ~poiypropyiene mesh scrim mata~al having a basis weight of about 100 grams per square mesa and available as P 100 (also designated PC-52) polypropylene mesh scrim from Smith and Nephew Plastics, Ltd. of 20 Gilberdyke, North Humberside, tJK. A sheet of such a mesh scrim has about relatively thicker and stiffer primary strands per centimeter (16 strands per inch) running in the sheet machine direction sad about 61 relstivdy thinner and less stiff secondary strands per centimeter (24 strands pa inch) cunning papertdicular to the Primary suands in the shett_cross rnachirre direction. The 5nt element 110 can 25 comprise a 6.0 mm wide strip of the P 100 (PC-52) mesh ast paralld to the primary strands, so that the primary strands extend along the length of the 5rst element l 10, and generally paraUd to the longitudinal axis 29 of the sarvnry napkin 20.
Another suitable mataid from which the first dement 110 can be formed comprises a polypropylene mesh scrim having a basis weight of about 50 grams per square inner 30 (10 lbsI1000 square feet) available as ON7100 polypropylene mesh 5rom the Conwed Comparry of Minneapolis, Mumaota.
The elastic second and third demerits 120 and 130 can be formed !loin a number of types of elastic material including nanual or synthetic rubber strands, elastic woven or nonwoven mstaisls, and elastic films. One suitable material from 35 which the second and third danatts 120 and 130 cast be formed is an elastic tape sold by FulSa~ Inc. of Mrddletown, Rhode Island as ULTRAFLEX~Iodel 6EX29 elastic tape. The second and third dements 120 and 130 can each comprix a length of such an elastic tape having a width of between about 4.0 and 6.0 mm and a thickness of about 2.0 mm. Ahernuively, the dements 120 and 130 can each 40 comprix a 6.0 mm wide strip of EXX-500 elastic sheet mata~ial available from the * = Trade-mark w0 93~I7d37 PC1'NS93/Od090 _-.-;-5 Eaocon Chemical Company of Buffalo Crrove, Illinois. A lifting member 100 having a first element 110 formed of the above PC-52 polypropylene mesh scrim and second and third elements 120, 130 formed of the above LJLTRAFLEX tape is nonabsorbent, and has a wet caliper reduction which is less than about 20 percent of its dry caliper reduction, with the wet caliper reduction no more than about 8 10 percent.
The pleats 115 in the first element 110 can be formed by elastic contraction of one or both of the second and third elements 120,130 relative to the first element 110. For instance, the first element 110 can have a free (unstretched) length which is greater than the free length of the second element 120 and the third element 130.
15 The second and third elements 120 and 130 can be elongated relative to their free lengths and relative to the first element 110. While elongated, the first and second elements 120 and 130 can be attached to the first demert 110 at spaced apart locations along the length of the first dement 110. When the forces causing the elongation of the elastic elements 120 and 130 are released, the dastic elements 120 ZO and 130 wil) contract relative to the first element 110, thereby drawing the spaced apart attachment points on the first elemem I 10 together to form the pleats 1 I 5.
Pa~cauage elongation is determined by subtracting an elongated length from the free gage length, and dividing the difference by the free gage length. For elastic elements 120 and 130 formed from the ULTRAFLEX elastic tape listed above, a 25 suitable lifting member 100 with pleats 115 can be made by providing a percentage of elongation in the second and third demems 120 and 130 of between about 35 and about 400 pacxnt. The second and/or third elastic demarts 120 and 130 can be attached to the first dement 110 at locations spaced apart a distance of between about 25.4 rata (i.0 inch) and about 127 mm (5.0 inch) as measured when the elastic 30 deratctts are dongated and prior to gathering of the first. dement 110 by contraction of the second and third elements 120 and 130. .
The height H1 of the pleats 115 is at least about 10 mm, preferably at least about 15 mat, and more preferably at least about 20 millimeters to provide adequate displacement of the cattral core segmera 62 relative to the side core segments 64 and 35 66. In the anbodiment shown in Figure 4 the Z-dire~on haght H1 of the pleau is generally uniform along the length L of the lifting member 100. By way of example, the height H1 can be between about 20 mm to about 22 mm. The spacing L 1 between adjacent pleats 115' can be between about 15 mm and about 19 mm.
For a lifting member 100 having a first element foamed firom the P 100 (PC-52) mesh 40 scrim material listed above and having first and second elastic elements 120, 130 WO 93r17437 PCTIU595104090 x f formed from the ULTRAFLEX elastic tape listed above, such a uniform arrangement of pleats 115 can be obtained where the percentage of elongation in the second and third elements 120 and 130 is about 250 to about 300 percent and where the second and third elements 120 and 130 are attached to the first element 110 at locations spaced apart a distance of about 49 mm to about 52 mm as measured when the second and third elements 120 and 130 are elongated and prior to gathering the first element 110 by contraction of the second and third elements 120 and 130. A
lifting member 100 having a 5rst element formed from the above listed P100 (PC-52) mesh scrim material and having l5rst and second elastic elements 120, 130 formed tom the above Gated ULTRAFLEX tape can have a pleat height H1 of 22 mm and a spacing L1 of 16 mm where the percentage of elongation of the second and third elements j 120 and 130 is about 300 percent and where the second W O 95!1713'7 PCTnJ595ias090 == k f~
and third elements are attached to the first element at locations spaced apart a distance of about 50 millimeters as measured when the second and third elements are elongated.
While the height Fil is relatively uniform along the longitudinal axis ?9 in Figure 4, in other embodiments the Z-direction height of the pleats I 15 can vary along the longitudinal length L of the lifting member 100. CA Patent Application Serial Number ~ 2,179, 485 filed Deoetnber 19, 1994.
In another anbodimertt the lifting member 100 can comprix a wicking member for transporting body fluids in the Z-direction and along the length of the lining member 100. For instance, the plested first dement I10 can comprix a wicking m~~ ~d can transport body fluids longitudina!>'y along the length of the lifting m1~. and in the Z-direction from the central core xgment 62 and the wicking member 70 to the support member 80. A first pleated dement 110 which comprises a wicking mernber can be ~~~ ~m app or nonapatured plastic films, plastic mesh scrims, or elastic strands treated or formed to be hydrophilic. A
suitable first element 110 can be formed from a pofypropyl,~ met ~ such as the above PC-52 mesh sc:ira, treated or formed to be hydrophilic. The mesh scrim can be treated to be hydrophilic by depositing on its a lays of hydrophilic meltblown polyethylene 8ben, such as are available from the Fibateclt Corporation of Landisville, New Jersey. Alternativd~r~ the m~ ~ ~ ~ formed to be hydrophilic by including in the scrim resin additives that bloom to the surface of the scrim snd raider it hydrophilic. One such additive is a Xarttrex polypropylene resin available from the F~tmont Company of Ddawue. The elastic second and third daztatts 120 utd 130 can be forrrud from a variety of hydrophilic aperwred ~~ta~ inchtda:tg dastomaic films and nonwovens treated or formed to be hydrophilic. A suitable trtuaial from which the sxond and third dements 120 and 130 cart be formed is an dastomeric meltblown nonwoven with a basis weight of bum about 40 to about 120 grants per square metes cooed on both sides with a suitable su>rfiu;car~t to nuke the of the nonwoven hydrophilic. A suitable nonwoven is a thermoplastic polyurethane spunbond fabric such as ICartebo Urethane Spunbond available from the ICanebo Company of Osaka, Japan. A suitable surfactant with which the nonwoven can be traced is SILWET'~ surfactant manufactured by the ICI Company of Osaingen, Germany, Figure 10 illustrates an apparatus for forming a pleated lifting member 100 and * = Trade-mark .3 1~
PCT/L1S93i0s090 5 joining the lifting member 100 to another component of the sanitary napkin .0 In Figure 10, three continuously fed pieces of material are designated as components 1 l 10, 1120, and 1130. By way of example component 1110 can correspond to the first element 110, component 1120 can correspond to the elastic second element 120.
and component 1130 can correspond to the elastic third element 130. The 10 components 1120 and 1130 can be bonded to the componern I 110 at spaced apart locations along the length of the component 1110, such as with an adhesive.
The discussion below refers to adhesive bonding of the components 1100, 1200 and 1300, but 'rc will be understood thu other bonding methods can be used. For instance, the components can be thertnaUy or uhnuonically bonded together.
15 Alternatively, the components can be mechanically bonded together in a pressure biased nip between a relief patterned cyliirder and an amril cylinder according to the teachings of above referenced U.S. Puent 4,919,738 issued April 24, 1990 to Ball ee al..
The component I 120 is carried at a first web speed through a first nip formed 20 between a first pair of contprauon roils 1001, 1003 rotating at a first rotational sP~d. Aa adhesive applicator 1200 applies adhesive to a side of the component 1120 at spaced apart locations aRa the component 1120 exits the nip formed by rolls 1001, 1003. A suitable adhesive is F'urdley Adhesive I3Z031 available from the Findley Adhesive Company ~f Elmgrove, Wisconsin.
25 The component 1120, along with component 1110, is then directed into a second nip formed by a second pair of compression rolls 1005, 1007. The component 1120 is pressed into engagartern with the component 1110 by the second pair of rolls 1005, 1007 to adlu~vdy bond the componatts 1120 and 1110 together at spaced apart loations. The sup rolls 1005, 1007 cxn be chilled to prevent buildup 30 of the adhesive.
The suri~ae speed of the rolls 1005, 1007 carries the components 1120 and 1110 through the second nip at a second web spud glares than the first web sped at which the componart 1120 is carried through the flex nip. This web speed di$erauial stretches the component 1120, and thereby differentially elongates the 35 component 1120 relative to the component 1110 prior to intermittently joining the component 1120 to the component 1110. For example, if the compression rolls have the same diameter, the second pair of compression rolls 1005, 1007 can be rotated at a second rotational speed which is greater than the 5ra rotuiona! speed of the rolls 1001, 1003.
40 The intermittently joined components 1110 and 1120 adt the second nip and WO 95IZ'7457 PC'I'NS95I04090 -.~- _ 5 are carried around first and second reversing rolls 1011 and 1013 in a generally serpentine path. An adhesive applicator 1200 then applies adhesive to spaced apart locations on a side of the component 1110 not joined to the component 1120.
The web speed around the rolls 1011, and 1013 can be maintained equal to the second web speed to maintain the tensile elongation in the component 1120.
10 The intermittently joined componenu 1110 and 1120, along with the component 1130, are then directed around a roll 1015 to press the component into engagement with side of the component 1110 to which adhesive is intermittently applied. The 'component 1130 is thereby joined to the component 1110 at spaced apart locations. The web speed around the roll 1015 can be maintained equal to the 15 second web speed to maintain the tensile eiongations in the component 1120.
Prior to being joined to the component 1110, the component 1130 can be directed at a third web speed through a third nip formed by a third pair of compression rolls 1017, 1019 rotating at a third rotational speed. The third web speed can be less than the second web speed at which the components 1110, 1120, 20 and 1130 are carried around the roll 1015. This web speed differential suetches the component 1130, so that the component 1130 is differentially elongated relative to the componem 1110. If the third web speed is equal to the first web speed, the percent elongation of the component 1130 will be approximately equal to the percem elongation of the component 1120. Alternatively, if the third web speed is less than 25 (or greater than) the first web speed, the percent elongation of the component 1130 will be greater than (or less than) the percent elongation of the component 1120.
The combined components 1110, 1120, and 1130, along with a component 1150, can be dirated at a fourth web speed through a fourth nip formed by a fourth pair of compression rolls 1021, 1023. 'The component 1150 can be a continuous web 30 comprising one or more of the materials from. which the backsheet 50 and support member 80 are formed, or alternatively, a continuous web comprising one or more of the ~rutaials from which the topsheet 40, wicking member 70, and central core segment 62 are formed. An adhesive applicator 1200 can apply adhesive to a side of the component 1150 prior to engagement of the component 1150 with the 35 component 1130 in the fourth ctip. The assembly of components I 110, 1120, 1130, and 1150 can be combined in later operations with other sanitary napkin components to form a completed sanitary napkin 20.
The tension in the stretched components 1120 andlor 1130 can be relaxed, such as by reducing the web speed before or after the components 1110, 1120 and 40 1130 are combined with the component 1150 in the fourth nip. Once the tension in WO 93117137 ~ PCTlUS93IOd090 _~- _ 3 x f 5 the stretched components is relaxed, the stretched components will elastically contract relative to the component 1110, and thereby gather the component 1 110 to form pleats 115.
A IiRing member 100 having pleats 1 I S with a Z-direction height that varies along the length of the lifting member can be formed by varying one or more of the 10 web speeds with time. The elongation of the component 1120 relative to the component 1110 will then vary along the length of the intermittently joined components. Once the tension in the component 1120 is relaxed, the elastic contraction of the component 1120 relative to the component 11 l0 will vary along the length of the intermittently joined components, thereby forming pleats 1 I
5 having 15 different Z-direction heighu. The Z-direction height of the pleats 1 l5 can also be varied along the length of the lifting member 100 by holding the elongation of the component 1120 constant while varying the spacing at ,which the component 1120, while elongated, is attached to the component 1110. Alternatively, the Z-direction height of the pleats 115 can be varied by varying both the elongation of the 20 component 1120 and the spacing at which the elongated component 1120 is attached to the component 1110.
Figure 11 A shows an atrartgement for forming a pleated lifting member 100 and joining the lifting member 100 to a wicking member 70 and a support member 80. In Figure 11 A, three continuously fed pieces of material are designated as 25 components 2i 10, 2120, and 2130. By way of example, component 2110 corresponds to the first element 110 of the lifting member 100, component 2120 corresponds to the elastic second dement 2120, and component 2130 corresponds to the elastic third dement 130. Similarly, continuous webs 2070 and 2080 in Figure 11 A correspond to the wicking member 70 and the support member 80, respectively.
30 The component 2120 is lataally supported by a guide 2038. Likewise, the component 2110 is laterally supported by a guide 2038. The component 2120 is carried through a nip formed by a pair of stretching rolls 2005 and 2007. The rolls 2005 and 2007 are rotated to have a s<uface speed less than that of downsueam metes rolls 2025 and 2027 to thereby elongate the component 2120. Intermediate 35 the stretch rollers 2005, 2007 and the meter rolls 2025, 2027, the componenu 2 i I 0 and 2120 are carried through a nip formed by a pair of heat sealing rolls 2015 and 2017. The heat sealing rolls 2015, 2017 thermally bond the component 2110 to the elongated component 2120 at spaced apart locations along their lengths. The roll 2017 has a plurality of projections 2018 spaced apart around the circumference of 40 roll 2017 to provide the desired bond spacing along the components 2110 and 2120.

_-... ~_ _ =6 1c i~
For bonding components 2110 and 2120 comprising the above P100 (PC-52) mesh scrim and CtLTRAFLEX elastic tape, the surfaces of the rolls 2015 and 20 i 7 can be heated to about 300 degrees Fahrenheit, and the interference between projections 2018 and roil 2015 can be set to zero. The components 2110 and 2120 exit the nip formed by robs 2015 and 2017 thermally bonded together, with pleats 115 formed in 10 the component 2110.
An adhesive applicator 2028 applies adhesive to the component 2120 after the components 2120 and 2110 exit the nip formed by the meter rolls 2025 and 2027.
The adhesive applied by applicator 2028 serves to later bond the component 2120 to the component 2070 at downstream bonding rolls 2035 and 2037. Similarly, an 15 adhesive applicator 2029 applies a coating of adhesive to the components 2130 and 2080. The adhesive applied by the applicator 2029 serves to join the components 2130 and 2080 together as they are conveyed adjacent one anothrr, and also serves to later bond components 2130 and 2080 to the components 2110 and 2070, respectively, at the downstream bonding rolls 2035 and 2037.
20 Prior to bonding the components at the bonding rolls 2035 and 2037, the component 2070 is directed through a folding board 3000. Referring to Figure I
1 B, the folding board 3000 includes a an elevated tongue 3100 and folding plows 3200.
As the central portion of the component 2070 is carried over the tongue 3100 and the sides of the component 2070 are carried under the folding plows 3200, parallel 25 folds 2071 are formed in the component 2070 which correspond to the folds 71 in the wicking member 70.
After the component 2070 is folded, the components 2110, 2120, and 2130 are carried through the nip of the bonding rolls 2035 and 2037 between the components 2070 and 2080. The bonding roll 2035 includes a cira~mfarntiaVy extending groove 30 2036 for accommodating the components 2110, 2120, and Z 130 which are ~ndwichad between the components 2070 and 2080. The continuous laminate of components exiting the bonding rolls 2035 and 2037 is art to the desired length to form individual tissuerli»irtg member laminates 2050, each comprising a support member 80, a wicking member 70, and a tilling member 100 disposed between the 35 members 70 and 80. A cut and slip assembly, such is manufactured by the Curt G.
Joa Company of Sheboygan Falls, Wisconsin can used to cut the continuous components to the desired length. Such a cut and slip assembly can include a cutting roll 2044 and a vacuum drum 2045 for carrying the laminates 2050 to a downstream conveyor, at which point the laminates 2050 can be joined to one or more other 40 components of the sanitary napkin 20.

wo 9sa~ds~

5 The lifting member 100 shown in Figures l-5 has a longitudinally extending pleated element 110. Such a liming member has the advantage chat it can be relatively easily manufactured by the cominuous process described above, and maintains its resiliency even after being compressed for extended periods of time (e.g., when the sanitary napkin is packaged prior to use.) Of course, other lifting 10 members can be used 'without departing from the scope of the present invention.
Patent Application Serial Number 2,178,588 filet? Decanber 19, 1494 and Wi0 92/07535 15 ~ - ~ ~ . .
The wicking member 70 conveys body exudates from the certaal core segment 62 to the 5rst and second side core segments 64 and 66. The wicking member 70 20 tact also provide lateral support to the liilutg member 100. A preferred wicking manba 70 comprises one or more webs of celiulosic Sbers, each web having a basis weight of baween about 10 grams Per square metes and 65 grams Per square meter.
A P~~Y P~~ wicking manta 70 comprises a tissue paper web have a basis weight of about 42 gams per square mesa. The wicking member 70 is 25 preferably made according to the teachings of U.S. Patent 4,637,859 issued January 20, 1987 to Trokhau. _ The support member 80 transfer= loads from the lifting member 100 to the backsheet 50. The support member 80 preferably has a laieral width greater than the lateral width C of the lifting member 100 to distnbute loads from the lifting member 30 across a portion of the width of the backsheet 50. The support member 80 can also convey 1along its length arid width. A preferred support member 80 comprises one or more webs of cdluiosic fibers loving a basis weight of between about 10 grams per square meter and 65 grams Per square maer. A particuluiy preferred support member 80 comprise a tissue papa web hive a basis weight of about 42 35 grams pet square metes. 'she support member 80 is preferably made according to the tachang: of above refa~atced U.S. Pstent 4,637,859.
to the exploded view of Fgure 5, the core segmaas 62, 64, and 66 are joined to the secondary topsheet layer 46 by adhesive attachments 169. The adhesive at:achmertts 169 can comprise Ftrtdley I32031 hot meh adhesive.
Another 40 suitable adhesive from which attachments I b9 can be formed is Fmdley'"H4031 * = Trade-mark w0 93!17457 PCT/US95/04090 _t adhesive available from the Findley Adhesive Company. The central core segment is joined to the central portion 72 of the wicking member 70 by an adhesive attachment 177, and the side core segments 64 and 66 are joined to the backsheet 50 by adhesive attachments 179. The adhesive attachments 177 and 179 can comprise one of the Findley H2031 or H4031 adhesives listed above.
The second element 120 of the lifting member 100 is joined to the central portion 72 of the wicking member 70 by an adhesive attachment 187. The side portions 74 and 76 of the wicking member 70 are joined to the side portions 84 and 86, respectively, of the support member 80 by adhesive attachments 189. The adhesives attachments 187 and 189 can comprise one of the above Findley adhesives.
The third element 130 of the lifting member 100 is joined to the central portion 82 of the support member 80 by an adhesive attachment 191. The support member 80 is joined to the backsheet 50 by adhesive attachments 193. The adhesive attachment;
191 and 193 can comprix one of the above Findley adhesives.
The Applicants have found that the present invention improves the ability of a sanitary napkin to receive and hold body fluids. Applicants have found that compared to a sanitary napkin having a single piece airfeit core with no lifting member 100, the sanitary napkin 20 shown in Figures 1-5 provides equivalent body fluid holding capacity with a reduced quantity, of airfelt. In particular, the Applicants found that the sanitary napkin 20 shown in Figures 1-5 having a total of about 4.2 grams of airfeh in the core segments 62, 64, and 68 and about 1.4 grams of tissue Papa ~ ~ ~~ng and support members 70 and 80 provides equivalent fluid holding capacity compared to a sanitary napkin having a single piece airfelt core weighing about 9.2 grams.
Figures 6 and 7 show alternative embodiments of the present invention. In Figure 6 the wiciang member 70 comprises a pair of tissue webs 77 and 79. Each of the tissue webs 77 oral 79 has a central portion 72 disposed intermediate the lining member 100 and the central core xgment 62, and first and~second side portions and 76. The first side 74 of the tissue web 77 can be joined, such as by adhesive, to the first side portion 74 of the web 79. Sirzularty, the second side portion 76 of the tissue web 77 can be joined to the second side portion 76 of the web 79. An ~xTb~ 8~~8 ~~ ~ ~ ~~s~d intermediate the central portions 72 of the tissue webs 77 and 79. The lifting member 100 displaces the absorbent gelling material 90 in the Z-direction relative to the side core segmerns 64 and 66.
The absorbent gelling material 90 can be adhesively joined to one or both of the tissue webs 77 and 79. The absorbent gelling material 90 serves as a storage zone for body _ .9 i~
5 liquids passing through the central core segment 62. and increases the liquid holding capacity of the sanitary napkin 20 over that which is available in the core segments 62, 64, and 66 alone. The arrangement shown in Figure 6 provides the advantage that the absorbent gelling material 90 is positioned adjacent the central core segment 62, and can thereby rapidly acquire body fluids deposited along the longitudinal 10 centerline 29 of the sanitary napkin 20.
An sbsorbem gelling material is a material which swells upon wetting and absorbs st least about 20 times its weight in wiser, Such abso~t gelling materials include but are not limited to silica gds and organic compounds such as crosslinked polymers. Partiarlarly preferred absorbent gelling materials are hydrolyzed 15 acrylonittile grafted starch, acrylic acid grafted surch, polyscrylata and isoburylene malefic anhydride copolymers, or mixtures thereof. U.S. Patent Re 32.649 reissued to Brandt et al. April 19, 1988.
In Figure 7 the support member 80 comprises a pair of tissue webs 87 and 89.
20 Each of the tissue webs 87 and 89 has a cerarai portion 82 disposod intermediate the lifting member 100 and the backsheet 50, and i5lrst and second side portions 84 and 86. The 5rst side portion 84 of the tissue web 87 can be joined, such a by adhesive.
to the 5rst side portion 84 of the web 89. Sin>ilarly, the second side portion 86 of the tissue web 87 can be joined to the second side portion 86 of the web 89. An 25 absorbent gelling cnataiaJ 90 is disposed irttamediate the cutaral portions 82 of the tissue webs 87 and 89. The absorbent gelling muetial 90 car, be adhaively joined to one or both of the tissue webs 88 and 89. The absorbent gelling material 90 serves as a storsge zone for body liquids conveyed by the wicking member 70 from the carnal core segment 62. The estrangement shown is Figure 7 provides the advantage 30 that the lifting 100 does not lift both the central core segment 62 and the absorbatt gelling muerial 90, and the body fluids are contained a a location spaced from the wards body by the lifting manta 100.
Figures 8 and 9 disclose ahernate anbodiments of the present invention whaan the c~tral core seg:runt 62 comprises an acquisition zone 262A having a 35 density less than the density of the airfelt Fuss and sa;ond side core segments 64 and 66. The rdativdy low density acquisition zone 262A is positioned in the area of typical fluid deposition to quickly acquire and distribute liquids within the sanitary napkin 20. U.S. Patatt 4,834,735 issued May 30, 1989 to Alematty et al.
discloses high density absorbent manbers having Iowa density acquisition zones.
The relatively low density acquisition zone 262A

WO 95n7137 ~ PCTIUS95/04090 5 preferably has a density less than about 0.12 grams per cubic centimeter under a confining pressure of 0.1 pounds per square inch.
Referring to Figure 8, the acquisition zone 262A is positioned along the longitudinal centerline 29 so that the lifting member 100 displaces the acquisition zone 262A in the Z-direction relative to the side core segments 64 and 66. The 10 acquisition zone 262A is registered with an opening 47 in the secondary topsheet layer 46 so that fluids deposited on the body facing surface 42 of the topsheet 40 along the longitudinal centerline 29 can directly enter the acquisition zone 262A from the primary topsheet layer 44. The acquisition zone 262A can be positioned intermediate relatively higher density forward and rearward airfelt segments 15 and 262C.
In one embodiment acquisition zone 262A is constructed to transport body fluids passing through the opening 47 in a direction generally parallel to the longitudinal centerline 29 of the sanitary napkin 20. A portion of the body fluids carried firm the opening 47 toward the ends 30A and 30B by the acquisition zone 20 262A are then stored in the airfelt segments 262B and 262C, and the remaining body fluids are transported laterally and in the Z-dir~on by the wicking member 70 for storage in the first and second side core xgmertts 64 and 66.
The acquisition zone 262A can comprix a plurality of longitudinally oriented capillary channel fibers 310 for transporting body fluids in a direction parallel to the 25 longitudinal centerline 29 of the sanitary napkin 20. Portions of the capillary channel fibers 310 registered with the opening 47 are preferably bonded to the primary topsheet layer 44, such as by adhesive bonding, to enhance transfer of body fluids from the topsheet 40 to the acquisition zone 262A. By "longitudinally oriented" it is meant that the fibers 310 extend in a direction generally parallel to the longitudinal 30 centerline 29 of the sanitary napkin 20. The term "capillary channel fiber"
refers to a fibs having a cross-section forming an open channel passageway for transporting fluid along the lrngth of the fiber. The fiber cross-section can comprix a number of different shapes, including but not limited to C-shapes, V-shapes, and H-shapes. The following documents are incorporated by reference for the purpox of disclosing such 35 capillary channel fibers: U.S. Patent 5,281,208 issued January 25, 1994 to Thompson et al.; U.S. Patent 5,200,248 issued Apri16, 1993 to Thompson et al;
PCT
Publication WO 93/02235 Fiber Capable of Spontaneously Transporting Fluids published February 4, 1993 in the name of Phillips and having a U.S. Ptioriry date of July 23, 1991; and EP Application 0391814 Fibers Capable of Spontaneously 40 Transporting Fluids published October 10, 1990 in the name of Phillips and having a _ PCT/US93/Od090 f 5 U.S. Priority date of April 4, 1989.
The acquisition zone 262A can comprise a tow bundle of longitudinally oriented capillary channel fibers 310. The term "tow bundle" refers to a collection of generally parallel fibers having substantially the same fiber length. The tow bundle of capillary channel fibers can have a total denier of between about 25,000 to about 10 60,000 grams per 9000 meters of tow length, and can have a total weight of about 0.25 gram to about 1.5 gram. The capillary ch~el fibers 310 in the cow bundle are preferably located in at least the central third of the sanitary napkin 20 as measured along the longitudinal centerline 29, and can extend substantially the fuU
length of the absorbent core 60, as shown in )rtgure 8.
15 In one embodiment, the tow bundle of capillary channel fibers 310 can have a total denier of about 50,000 and a weight of about 1.0 gram. The fibers 310 can comprise helically crimped polyethylene-terephthalate (PET) fibers having a crimping frequenry of about 3 crimps per inch, a crimp amplitude of about 0.45 mm, and a relatively deep C shaped cross-section having a channel width of about 55 micron 20 and a channel depth of about 102 micron, with a denier per fiber of about 24 grams per' 9000 meters. Such a tow bundle of fibers is manufactured by the Eastman Chemical Company of Kingsport, Tennessee under the de~gt>ation 4SW "Deep C"
CX Low Crimp Helical Tow, SW-405.
In another embodiment, the tow bundle of capillary channel fibers 310 can 25 have a total denier of about 25,000. The fibers 310 can comprise helically crimped PET fibers having a crimping frequency of about 2.5 crimps per inch, a crimp amplitude of about 0.9 mm, and a C-shaped cross-section having a channel width of about 53 microns and a channel depth of about 50 microns, with a denier per fiber of about 10 grams per 9000 meters, Such a tow bundle of fibers is manufactured by the 30 Eastman Chemical Company under the designation 4SW "Spread C" CX, Low Crimp Helical Tow, SW407.
~ Y~ ~~a anbodimertt, the acquisition zone 262A can comprise a carded sliver of staple fibers having a total denier of about 60,000 grams per 9000 meters of sliver length. The fibers of the carded sever are longiwdinally oriented and can have 35 a 6 inch staple fiber length and a fiber denier of about 27 grams per 9000 meters of fibs length. The fibers can be helically crimped PET fibers with a crimping frequenry of about 6 gimps per inch, a crimp amplitude of about 0.5 mm, and an H-shaped cross-section having a channel width of about 43 microns, a channel depth of about 61 microns, and a denia per fiber of about 27 grams per 9000 meters.
Such a 40 carded sliver is manufactured by the Eastman Chemical Company under the wo 9sm~sr rcrrt~s9s~oso9o _ 3:
r 5 , designation 4SW "Fi" C?L Carded Staple Sliver. SW404 In yet another embodimem the acquisition zone 262A can comprise cross-linked cellulosic fibers. U.S. Patent 5,183.707 issued February 2, 1993 to Herron et al. - - - _ ..
10 In the embodiment shown in Figure 9, the acquisition zone 262A comprises a tow bundle of longitudinally oriented capillary channel fibers 310 disposed between bonded fibs layers 320. The tow bundle of capillary channel fibers 310 is joined to the bonded fiber layers 320 by any suitable mans, including but not limited to adhesive bonding and ultrasonic bonding. The bonded fibs layers 320 serve to 15 rapidly acquire body fluids, and the tow bundle of longitudinally oriented capillary channel fibers 310 distributes the acquired body fluids in the longitudinal d;~on.
The tow bundle of capilluy channel fi>~ 310 can have a total denier of about 25,000 and comprise PET fiber: having a C-shaped cross-section with a channel width of about 50 microns cad a channel depth of above 99 microns, with a denier ZO per fiber of about 22 grams per 9000 m~. Such s tow of fibers is manufactwed by the Eamnan Chemical Company undo the designation 4SW "Deep C" CX, Uncrimped Tow, SW4p6. ?ha tow bundle of capillary champ( fibers 310 can have a total weight of about 0.5 grams The bonded fiber layers 320 comprise a bonded network of capillary channel 25 fibers and bicomponem binder fibers. The bonded network can comprise about percent by weight capillary channel fibers and about 10 percent by weight bicomponatt binds fibers. The bicomponent binder fibers can be thermoplutic b~'a fibers such is DANAKLON~ ES C 1.7 dtex x b mm crimped bicomponent . The capillsry chamtd fiber of the bonded fiber layers 320 can be Qimped, staple length PET fibers having a C-shaped cross-section and a staple length of about 1.5 inch. TtK capillary ch:nnet fibers can have a crimp fiequaxy of about 7.5 camps pa inch a gimp amplitude of about 0.4 mm, a channel width of about 52 microns, cad a channel depth of shout 47 microns.
Such fibers are manu5cdrred by the Easonan Chemical Company under the designation 35 SW408. The bounded layers 320, combined, can irtdude about 0.45 grams of the ~p~ ~d fibers and about 0.05 grams of the bicomponeru binder fibers. The network of fibers cxn be formed and tltamaily bonded as described in ~ Patent Application Serial Number 2,173, 943 filed October 20 . .1994. .._ ._ __ wo s~~~s~
PCTNS93IOIO9p The bonded layers 320 can have a density of about 0.02 to about 0 06 gram per cubic under a confining pressure of about 0.1 pounds per square inch and a basis weight of between about 15 to about 45 grams per square meter.
In another embodiment the bonded layers 320 can have a basis weight of about 30 grams per square metes, a density of about 0.035 gram per cubic centimeter under a confining pressure of about 0.1 pounds per square inch. and a Z-direction thickness of about 0.8 mm under a 0.1 pound pa square inch confining pressure. The bonded layers 320 can, comprix about ninety percent by weight PE1 capillary, channel fibers and about 10 pa~cent by weight bicomponerrt binder fibers. The binder fibers can comprix DANAId.ON ES C 1.7 dtex 6mm bicomponerrt fibers. The capillary channel fibers can have s denier per fibs of 22 grams per 9,000 meters, a crimp frequency of 3.6 crimps per inch, a cximp amplitude of about 0.29 mm, a channql width of about 49 microns, and s charred depth of about 97 microns. Such fibers are manufacaued by the Eastman Chanica) Company under the designation SW376.
While particular embodiments of the praatt invention have been illustrated and described, the scope of the present invention is defined by the sppended claims.

Claims (5)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A mold for forming an airlaid absorbent core, the mold comprising:
a mold top surface;
a deposition cavity formed in the mold top surface, the deposition cavity bounded by a perimeter sidewall and a foraminous bottom wall; and as least one partition dividing the deposition cavity into cavity segments.

2. The mold of claim 1 comprising a pair of generally parallel partitions.

3. The mold of claim 2, wherein the mold forms a portion of the perimeter of a laydown drum, and wherein the partitions extend generally parallel to the direction of rotation of the laydown drum.

4. The mold of claim 2, wherein each partition comprises a passageway for interconnecting adjacent cavity segments.

5. A method for forming a segmented absorbent core, the method comprising the steps of:
providing a source of vacuum;
providing a mold, the mold comprising:
a mold top surface;
a deposition cavity formed in the mold top surface, the deposition cavity bounded by a perimeter sidewall and a foraminous bottom wall, the foraminous bottom wall in flow communication with the source of vacuum; and at least one partition dividing the deposition cavity into segments, each partition providing an interconnection between adjacent cavity segments;
depositing material into each of the cavity segments to form interconnected core segments; and separating the interconnected core segments subsequent to forming the interconnected core segments.