EP3638183A1 - Absorbent core assemblies, ergonomic disposable absorbent undergarments making use of such core assemblies, and methods of making the same - Google Patents
Absorbent core assemblies, ergonomic disposable absorbent undergarments making use of such core assemblies, and methods of making the sameInfo
- Publication number
- EP3638183A1 EP3638183A1 EP18817238.1A EP18817238A EP3638183A1 EP 3638183 A1 EP3638183 A1 EP 3638183A1 EP 18817238 A EP18817238 A EP 18817238A EP 3638183 A1 EP3638183 A1 EP 3638183A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- section
- layer
- pockets
- sap
- absorbent
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/15577—Apparatus or processes for manufacturing
- A61F13/15585—Apparatus or processes for manufacturing of babies' napkins, e.g. diapers
- A61F13/15593—Apparatus or processes for manufacturing of babies' napkins, e.g. diapers having elastic ribbons fixed thereto; Devices for applying the ribbons
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/45—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the shape
- A61F13/49—Absorbent articles specially adapted to be worn around the waist, e.g. diapers
- A61F13/49007—Form-fitting, self-adjusting disposable diapers
- A61F13/49009—Form-fitting, self-adjusting disposable diapers with elastic means
- A61F13/49019—Form-fitting, self-adjusting disposable diapers with elastic means the elastic means being placed longitudinally, transversely or diagonally over the article
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F13/531—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having a homogeneous composition through the thickness of the pad
- A61F13/532—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having a homogeneous composition through the thickness of the pad inhomogeneous in the plane of the pad
- A61F13/5323—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having a homogeneous composition through the thickness of the pad inhomogeneous in the plane of the pad having absorbent material located in discrete regions, e.g. pockets
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F13/534—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F13/534—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad
- A61F13/537—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F13/534—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad
- A61F2013/53445—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad from several sheets
Definitions
- This invention relates generally to disposable absorbent products and more particularly to disposable absorbent garments for adults, absorbent core assemblies for such products, and methods of making absorbent core assemblies and disposable absorbent products, such as disposable absorbent garments for adults, wherein the each garment includes an absorbent core assembly.
- the Undergarments are commercially available today from various manufacturers for use by adults having problems with incontinence. Examples of such products are men's and women's briefs sold under the trademark Depend® by Kimberly-Clark Corporation.
- the Depend® products utilize a chassis mounting an absorbent core in the crotch region of the chassis.
- the chassis itself comprises a colored nonwoven with approximately fifty seven transversely extending strands of white spandex elastic threads laminated between layers of a nonwoven spunbond fabric to impart elasticity to hold the undergarment close to the body of the wearer.
- the spacing between the elastic fibers is relatively large, e.g., 6 - 7 mm, so that the chassis exhibits a somewhat puckered appearance.
- chassis for holding an absorbent core
- the chassis includes a plurality of transversely extending elastic threads or filaments to render the undergarment close- fitting in the interest of concealability and wearer comfort.
- Proctor & Gamble offers incontinence underwear under the trademark Always®.
- That product also makes use of a chassis comprising approximately fifty seven transversely extending and relatively widely spaced strands of white spandex elastic threads sandwiched between two layers of a nonwoven spunbond fabric.
- the chassis mounts an absorbent core and includes six additional colored elastic threads in the rear of the chassis to serve as an indicator of the back side of the product.
- the Always® products also exhibit a somewhat puckered appearance.
- LivDryTM Livedo, USA offers an incontinent brief under the trademark LivDryTM. That product makes use of a chassis having approximately forty widely spaced transversely extending white spandex elastic strands in panels laminated between two layers of white spunbond fabric, plus an additional eight colored elastic spandex strands in the rear of the product to serve as an indicator of the back side of the product. Like the Depends) products and the Always® products, the LivDryTM products also exhibit a somewhat puckered appearance.
- many current adult disposable absorbent products utilize what is known as a fiberized bleached wood fluff pulp and a SAP (Super Absorbent Polymer) mixture for the absorbent core.
- SAP Super Absorbent Polymer
- the core mixture may or may not be wrapped in an absorbent tissue to prevent the SAP from falling apart or out of the core.
- the core must be wrapped to prevent the loose SAP from being shaken out.
- a core adhesive may be added to prevent the heavier SAP particles from being separated from the fluff pulp fibers.
- the pulp fiber in these products is required to rapidly manage the body fluid exudates until the SAP can desorb the fluff fibers to prepare the fluff fibers for the next exudates. For an adult the amount of exudate is can easily exceed 300 ml. or more delivered over a time period of more than 70 seconds at a rate similar or less than what infants void.
- the current state of the art product design for the synthetic absorbent cores is based upon a synthetic continuous fiber matrix inter-layered with SAP.
- a synthetic continuous fiber matrix inter-layered with SAP For example a polypropylene tow fiber similar to tow used in cigarette filter making was chosen. This material is purchased in a continuous fonn and is pulled out of the box and proceeds into an air trumpet or similar device or the like, to expand the fiber tow matrix. Then SAP particles are intermixed, adhesive is sprayed into the fiber SAP matrix and the entire matrix is wrapped to result in what is the state of the art of current so-called "pulp-less" core technology.
- This type of core has the major limitations of a slow absorbency rate. That rate is highly dependent upon the SAP chosen and on the adhesive type and amount required to attach the SAP to the tow fiber matrix.
- the SAP may limit the SAP's absorbent swelling due to coating part of the SAP particles. If less adhesive is utilized, while it may permit greater swelling and absorption of the exudate by the SAP, it may allow the SAP particles to fall from their positions in the core to the bottom of the crotch area, rendering it heavier and wetter in the crotch area when voided into and less absorbents at the ends.
- SAP pulp-less core technology
- This bonding process may limit the SAP from being fully expanded and utilized in absorbing the exudate.
- the SAP may also be applied in continuous rows to provide space for the fluid to travel unhindered.
- the SAP may be intermixed with ground wood pulp fibers of similar size to enhanced fluid movement in this inefficient design.
- the absorbent core assembly is composed of two sections of SAP for quickly and securely absorbing voided liquid without leakage.
- One section of the core which is located facing the wearer's body, includes a plurality of pockets partially filled with a free, slow acting, but highly absorbent SAP.
- the other section of the core is located facing away from the wearer's body and includes a plurality of pockets partially filled with a free, fast acting, but lower absorbency SAP.
- bleached absorbent pulp roils are then shipped to the absorbent garment manufacturer, also known as a converter.
- the rolls of bleached wood pulp are subsequently processed through a fiberizing hammer mill on the production converting line to fiberize the bleached softwood absorbent pulp into discreet fibers.
- From the hammer mill tliese fibers are conveyed by air to either a continuous tissue layer on top of a screen like material with vacuum under said system or into a pocketed shaped screen on a rotating drum pulled into the pocket shape by vacuum.
- These hammer mills require high levels of energy to rotate the hammers at approximately ten thousand revolutions per minute, usually requiring 720-volt power supply limiting such equipment to heavy industrial power grid areas with a large voltage and amperage power supply.
- the hammer mills and subsequent supporting process also cost approximately one million dollars or more.
- Some processes used today have two such million-dollar hammer mills processes.
- these processes require substantial amounts of compressed air, vacuum and an extensive air filtration system to filter out substantial amounts of dust. This is required for both a single absorbent product converting machine and the entire factor ⁇ '. If it contains more than one such machine, substantially more equipment is required. All adding to the cost of the million-dollar hammer mill systems. Because of the noise of these hammer mills operators are required to wear hearing protection to negate some of the noise . Hearing protection can also prevent operators from effectively communicating with each other, which may contribute to on the job accidents.
- SAP super absorbent polymer
- chemically it is polymerized polyacrylic acid, partially neutralized with sodium hydroxide.
- Other additives may be added in the polymerization process or topically added during the drying process to enhance desired differences.
- This SAP material increases the total capacity of the absorbent system without adding additional fiberized wood pulp.
- the advantage of SAP is to assist in desorbing or pulling moisture away from the fiberized wood pulp to increase the dryness of such a system.
- the disadvantage of SAP is its slow absorbing properties that cause such absorbent systems to require fiberized wood pulp to manage fluid insult speed. In some cases, the SAP is further modified to increase absorbent speed, but this reduces absorbent capacity and results in the issue of gel blocking.
- Gel blocking is the problem of the outer SAP particles absorbing fluid, swelling and blocking or preventing the fluid from reaching the inner SAP particles.
- the SAP particles are also conveyed by air into the fiberized pulp stream to create the desired ratio of fiberized wood pulp to SAP (frequently referred to as the pulp/SAP ratio). With higher ratios above 30% or more, a tissue wrap maybe required. Whereas lower amounts of SAP or a ratio below 30% may not require a tissue wrap.
- Usually no additives or a slight amount of misted water or mineral oil and the like are added into the hammer mills to enhance processability.
- a small amount of an absorbent core adhesive may be used to add integrity to the fluff /SAP absorbent core. This has the drawback of gumming up the process, so it has not been universally accepted and utilized in this type of construction.
- Dual forming fluff pulp systems are used by some absorbent product manufacturers to overcome some of the above noted problems.
- some modifications of such existing pulp/SAP absorbent products production systems include using a dual or double fibenzing system.
- the absorbent core is composed of two layers, usually including SAP in both layers. This is to provide for marketing and advertising claiming "dual core.”
- There may be a small improvement in providing more consistency in the absorbent core if it incorporates two similar pulp/SAP ratios.
- the manufacture of such absorbent cores may choose to use a different pulp in the body side layer than the away from body side layer. In some cases, this could be a highly crosslinked cellulose pulp "curly fibers" or like materials is usually found in the body side layer.
- the manufacturer may choose to add a higher level of SAP in the body side layer to promote dryness, depending upon the away from the body layer to manage absorbency speed. This only increases dryness slightly, also known as "rewet" or wet back against the body.
- total absorbency or absorbent capacity is dependent upon the total amount of SAP, fluff pulp and tissue, and their inherent absorption capacities, regardless of the construction. In all cases referenced previously, these processes require a large, energy intensive, noisy fiberization system with immense vacuum and dust collection systems.
- the absorbent product contains fiherized wood pulp to manage the speed of the absorbent insult from the wearer's body.
- a usual body void is about 150 to 250 ml over about 70 to 90 seconds.
- the SAP by itself does not adequately absorb fluid at such a fast rate.
- fiberized fluff pulp is required to manage the initial speed.
- Airiaid absorbent is constructed of fiberized wood pulp that is usually mixed with up to 70% SAP and either adhesively bonded or thermally bonded and compressed into a thick paper like material. Airlaids without S AP are sold as high-end or expensive disposable paper napkins or the like. While such absorbent cores have a greater thinness than pulp/SAP absorbent cores, they necessarily have a slower absorbent speed and reduced total capacity per gram of Airiaid due to the bonding under pressure to make the absorbent core thinner. Moreover, cost is increased for this type of approach due to the energy required to thermally secure or glue this construct together.
- Airiaid cores are usually created at a different facility and shipped to the converting facility.
- the deficiency in absorption speed has delayed introduction of such products into any markets.
- Another alternative absorbent core produced from about 2003 to 2005 has been an absorbent core composed of cellulose acetate fibers with free SAP mixed in and wrapped with a heavier weight tissue.
- the advantage of such an absorbent core is comfort as it will not be as insulating and warm as a product manufactured containing cellulose fluff pulp.
- the disadvantage is absorbency rate and speed.
- Such a system is not as fast as required to handle a full absorbent void from, infants or adults.
- a product sold using this construct was Parent's Choice Protective Underwear sold by Waimart, Inc. from approximately 2003 to 2005. It was an adequate product for a child pull up that is meant to be used only once as it was a toilet training absorbent back up product for slight accidents.
- This product was known to have the desired reduced thermal insulating properties compared to a fiberized cellulosic containing product. Children, who were well k now n for removing typical pulp based pull-up like absorbent garments, due to being uncomfortably warm to the body, did not remove these products. Another variant of this product was a baby diaper seen in the Middle-East produced by RK Beaufort and incorporated polypropylene filaments in place of the cellulose acetate fibers to reduce cost. Due to the high compressibility of these products compared to standard fiberized wood pulp/SAP, these products were desirable due to the lower cost of transportation.
- Another approach to constructing an absorbent core includes a system developed by Migaku Suzuki, Ph.D., of the Japan Absorbent Technology Institute (known as J ATI).
- Dr. Suzuki ground the pulp much finer than is created by a hammer mill, which fiberizes sheets of wood pulp. With similar particle size when compared to SAP particles, both sets of particles are glued to a back sheet or other material . This creates an extremely thin absorbent core.
- the resulting absorbent core is still unable to manage the speed of an absorbent insult due to the slowness of the SAP and predicated upon the speed of the glue to delaminate from the SAP particles.
- cost is dramatically increased with the addition of an adhesive and the secondary processing required to grind the wood pulp into a smaller size.
- the spacing between immediately adjacent elastic threads is approximately 5 mm.
- the elastic threads are colored so as to be readily visible from the exterior of the undergarment.
- the core comprises a fluid acquisition layer disposed over the first section of the core.
- Each of the first and second layers are configured to permit the migration of a liquid therethrough and are quilted by fixedly secured securement lines to form a plurality of first pockets in the first layer and a plurality of first pockets in the second layer.
- Each of the first pockets is partially filled with a free, slow acting but high absorption capacity SAP.
- the second section is formed of a layer of porous material of configured to permit the migration of a liquid therethrough.
- the layer of the second section is quilted to form a plurality of second pockets.
- Each of the second pockets is partially filled with a free, fast acting but lower absorption capacity SAP, wherein the voiume of SAP in at least some of the second pockets is within the range of approximately 20 - 30 percent of the volume of the second pockets.
- the core is configured whereupon fluid voided by the person flows to the fast acting SAP and to the slow acting SAP, wherein the fluid is absorbed quickly and rapidly by the fast acting SAP, while the slow acting SAP desorbs or takes fluid away from the fast acting SAP as well as absorbing the fluid itself.
- vortex time represents the amount of time that it takes SAP which is mixed with water in a vessel by a spinning stirrer to form a gel to stop the spinning stirrer.
- the first section forms a body-facing side disposed confronting the perineum region of the person.
- the second section is located below the first section and is in fluid communication with the first section.
- the second section has a predetermined width and length.
- the second section is formed of a layer of porous material of configured to permit the migration of a liquid therethrough.
- the layer of the second section is quilted to form a plurality of second pockets.
- the first section comprises a third layer is fonned of a porous material configured to permit the migration of liquid therethrough and is quilted by fixedly secured securement lines to form a plurality of first pockets in the third layer, with each of the first pockets of the third layer being partially filled with a free, slow acting but high absorption capacity SAP.
- the first section forms a body-facing side disposed confronting the perineum region of the person.
- the second section is located below the first section and is in fluid communication with the first section.
- the second section is fonned of a Saver of porous materi al of configured to permit the m igration of a liquid therethrough.
- the layer of the second section is quilted to form a plurality of second pockets.
- Each of the second pockets is partially filled with a free, fast acting but lower absorption capacity SAP.
- Each of the second pockets is diamond shaped has a first pair of diametrically opposed comers and a second pair of diametrically opposed comers, and wherein second pockets are oriented so that the first pair of diametrically opposed comers extend parallel to the longitudinal axis.
- the diamond shaped pockets are square and in the range of approximately 1.5 cm by 1.5 cm to 3.0 cm. by 3.0 cm.
- the outer first pockets make up approximately two thirds of the width of the first absorbent section.
- the plurality of pre- stretched elastic threads includes a first plurality of pre-stretched elastic threads extending parallel to the top front edge and to each other from one of the pair of front side edges to the other of the pair of front side edges, a second plurality of pre- stretched elastic threads extending parallel to the top back edge and to each other from one of the pair of back side edges to the other of the pair of back side edges, and a third plurality of pre-stretched elastic threads extending parallel to the front top edge, to the back top edge, and to each other from one of the pair of central side edges to the other of the pair of central side edges.
- Plural ones of the plurality of pre- stretched elastic threads are cut into separated segments at the location of the absorbent core receiving region.
- the spacing between immediately adjacent elastic threads is in the range of approximately 4 - 5 mm.
- the plurality of pre-stretched elastic threads of the front section extend from a point closely adjacent the top front edge to the intermediate section, and wherein the plurality of elastic threads of the back section extend from a point closely adjacent the top back edge to the intermediate section.
- the pre-stretched elastic threads in the portions of the chassis between the waistband portion and the crotch section exhibit a gradient of tension or stretchability which decreases towards the crotch section.
- Each of the second pockets is partially filled with a free, fast acting but lower absorption capacity SAP.
- the first section of the absorbent core assembly and the second section of the absorbent core assembly are in fluid communication with each other, with the second section of the absorbent core assembly located closer to the chassis than the second section of the absorbent core assembly.
- the chassis additionally comprises a second sheet of a similar size and shape to the first sheet.
- the chassis is formed by applying a layer of adhesive on a surface of at least one of the first and second sheets.
- a plurality of pre-stretched elastic threads is provided on the layer of adhesive.
- the first and second sheets are brought together to sandwich the plurality of pre-stretched elastic threads between the first and second sheets.
- the absorbent core assembly is made by providing a first section of at least one layer of a porous material configured to permit the migration of a liquid therethrough.
- the at least one layer of the first section is quilted by fixedly secured securement lines to form, a plurality of first pockets.
- Each of the first pockets is partially filled with a first volume of a slow acting, but high absorption capacity SAP therein.
- a second section of at least one layer of a porous material configured to permit the migration of a liquid therethrough is provided.
- the at least one layer of the second section is quilted by fixedly secured securement lines to form a plurality of second pockets.
- Each of the second pockets is partially filled with a second volume of a fast acting but lower absorption capacity SAP therein.
- the second volume is different than the first volume.
- the first section is disposed over the second section so that they are in fluid communication with each other, whereupon the resulting core is configured such that a liquid contacting the first section flows through the at least one layer of the porous material of the first section into the first pockets and from there flows through the at least one layer of the second section into the second pockets to be absorbed quickly and rapidly by the fast acting SAP therein, while the slow acting SAP desorbs or takes liquid away from the fast acting SAP as well as absorbing the liquid itself.
- the method of making the disposable absorbent undergarment of this invention additionally comprises providing a wicking layer disposed between the first and second sections to enhance liquid transfer between the first and second sections.
- the method of making the disposable absorbent undergarment of this invention additionally comprises providing a fluid acquisition layer disposed over the first section.
- the absorbent core assembly additionally comprises a liquid barrier layer formed by a web of barrier material.
- the method additionally comprises disposing the web of barrier material under the second section.
- the composite web is provided to a converting production line for making a plurality of disposable absorbent adult incontinence products, infant absorbent garments, diapers, sanitary napkins, panty liners, or any other absorbent product arranged to absorb liquids from a being.
- the composite web is provided to make a plurality of absorbent undergarments, each of the undergarments including a chassis has a region for receipt of the absorbent core assembly.
- the chassis comprises a first and second sheet.
- Each of the sheets is of a similar size and shape, wherein the chassis is formed by applying a layer of adhesive on a surface of at least one of the first and second sheets.
- a plurality of pre-stretched elastic threads is disposed on the layer of adhesive. The first and second sheets are brought together to sandwich the plurality of pre-stretched elastic threads between the first and second sheets.
- the method additionally comprises cutting plural ones of the plurality of pre-stretched elastic threads into separated segments at the location of the absorbent core receiving region.
- Fig. 1 is an isometric view of one exemplary absorbent undergarment constructed in accordance with this invention and including an aesthetically pleasing, thin chassis and an absorbent core assembly mounted within the chassis;
- Fig. 2 is an enlarged top plan view of the absorbent undergarment of Fig. 1, but shown in its laid-flat state immediately preceding the sealing of its marginal edges to complete the undergarment;
- Fig. 2A is an illustration of chassis shown in Fig. 2;
- Fig. 3 is an enlarged sectional view taken along line 3 - 3 of Fig. 2;
- Fig. 5 is an enlarged sectional view taken along line 5 - 5 of Fig. 2;
- Fig. 6 is a top plan view of one exemplary absorbent core assembly of the undergarment shown in Figs. 1 and 2;
- Fig. 9 is a top plan view of a fluid-transfer or wicking layer forming an intermediate layer of the core assembly shown in Fig. 6;
- Fig. 10 is a top plan view of one multi-pocketed structure containing fast- acting but lower absorbency SAP particles within the pockets thereof, and which structure forms a layer of a lower section of the core assembly shown in Fig. 6;
- Fig. 17 is a greatly enlarged sectional view, not to scale, taken along line 17 - 17 of Fig. 12;
- Fig. 19 is a top plan view, like Fig. 7, but showing an alternative multi- pocketed structure containing slow-acting but high absorbency SAP particles within the pockets thereof, and which structure forms one layer of an upper section of yet another alternative embodiment of a core assembly constructed in accordance with this invention;
- Fig. 20 is a block diagram showing one exemplar ⁇ ' method of this invention for forming an absorbent disposable undergarment, e.g., an adult brief;
- Fig. 21 is a block diagram of exemplary steps for forming the top or first section of an absorbent core assembly for use in the absorbent disposable brief or other absorbent products;
- Fig. 22 is a block diagram of exemplary steps for forming the bottom or second section of the absorbent core assembly for use in the absorbent disposable brief or other absorbent products
- Fig. 23 is a block diagram of exemplary steps for forming (e.g., assembling) the absorbent core assembly for use in the absorbent disposable undergarment or brief or other absorbent products;
- Fig. 24 is a block diagram of exemplary steps for forming (e.g., assembling) the chassis for the absorbent disposable undergarment or brief;
- Fig. 25 is a block diagram, of exemplar ⁇ 7 steps for form ing (e.g., assembling) the absorbent disposable undergarment or brief from the absorbent core assembly and the chassis;
- Fig. 26 is an side elevation view illustration of a portion of a continuous converting system for carrying out one exemplary method of making the absorbent disposable undergarment or brief shown in Fig. 1;
- Fig. 27 is a top plan view illustration of a portion of an alternative continuous converting system for producing an alternative absorbent core assembly suitable for use as part of the absorbent disposable garment or bri ef shown in Fig. 1 ;
- Fig. 28 is an enlarged sectional view taken along line 28 - 28 of Fig. 27 showing the making of the alternative absorbent core of Fig. 27.
- Fig. 1 one exemplary embodiment of a disposable absorbent undergarment 10 constructed in accordance with this invention.
- the exemplary undergarment shown is in the form of a brief which is arranged to be worn by a person, e.g., an adult, under clothing to provide excellent fluid absorption and other capabilities in a construction that is comfortable to wear, easy to put on and take off, yet which is extremely thin and aesthetically pleasing so as to be virtually undetectable when worn under clothing.
- the brief includes a chassis 22 and an absorbent core assembly 24, each of which will be described in detail later. However, before doing that it must be pointed out that while the exemplaiy undergarment 10 of Fig.
- the core can be used in disposable absorbent products for children and babies, e.g., the core can be used in a chassis of a diaper. In fact, with appropriate modifications the core can be configured for use in a chassis suitable for use on pets.
- many of the various components of the disposable absorbent article, alone or in combination with each other are novel and provide significant utility for various other type absorbent products, e.g., feminine hygiene pads, panty liners, bandages, etc.
- the undergarment may include one or more of an odor reducing system, a treatment system, and a wetness detecting system . Any one or more of the odor reducing system, the treatment system and the wetness detecting system may incorporated in the absorbent core assembly 24 or located in the chassis 22.
- the chassis 22 is best seen in Figs. 1 - 5 and basically comprises an outer sheet or shell 26 and an inner sheet or shell 28.
- the outer sheet is formed of a clothlike, nonwoven breathable fabric, e.g., spunmelt polypropylene, or spunmelt polyethylene, or spunmelt polyester. If desired the outer sheet may be laminated to a barrier film like material, such as a 0.5 to a 1.1 mil polypropylene or polyethylene film.
- the film should be liquid impermeable to prevent leakage, e.g., an extrusion coated SMS or the like.
- the inner sheet 28 forms the "body-side" sheet of the chassis and is also formed of a non-woven, breathable material, e.g., spunmelt polypropylene, or spunmelt polyethylene, or spunmelt polyester, or the like.
- the inner and outer sheets are similarly sized and shaped, with the inner sheet disposed over the outer sheet and adhesively secured thereto by an interposed layer of an adhesive 30, e.g., such as Henkel 901 B construction adhesive or the like construction adhesives typically used in the manufacture of adult and infant disposable absorbent products to form the chassis as best seen in Fig. 3.
- a large plurality, e.g., approximately one hundred eighteen, of elastic filaments, fibers or threads 32, the details of which will be described later, are secured within the adhesive layer 30 and extend laterally across the full width of the chassis 22, except for a portion of the chassis which forms the crotch section of the undergarment.
- the elastic threads extend parallel to a transverse axis TX and are closely spaced from one another, e.g., approximately 4 - 5 mm apart.
- the elastic threads 32 are normally in a relaxed or un-stretched state when the undergarment is not worn. When worn the elastic threads stretch to cause the undergarment to closely conform to the anatomy of the wearer.
- the chassis includes a front or ' " belly” section 34, a back or " 'rear” section 36, and an intermediate or crotch section 38.
- the crotch section 38 is centered about a transverse a,xis TX
- a recess 40 is located in the right side edge of the chassis.
- a similarly shaped recess 42 is located in the left side edge of the chassis.
- the recesses form respective leg openings 44 (Fig. 1) of the undergarment.
- the right side recess includes a portion which is located in the front section, a portion that is located in the crotch section and a portion that is located in the rear section.
- the left side recess includes a portion which is located in the front section, a portion that is located in the crotch section and a portion that is located in the rear section.
- the front section 34 includes a top front edge 46, a right front side edge 48, a portion 50 of the right side recess 40, a top left front side edge 52, and a portion of the left side recess 42.
- the top front edge 46 is linear, as are the right front side edge and the left front side edges 48 and 52, respectively.
- the rear section 36 includes a top rear edge 56, a right rear side edge 58, a portion 60 of the right side recess 40, a left rear side edge 62, and a portion 64 of the left side recess 42.
- the top rear edge 56 is linear, as are the right rear side edge and the left rear side edges 58 and 62, respectively.
- the portions of the chassis 22 contiguous with the front side edges 48 and 52 form what are commonly referred to as the front section "ears" of the chassis, while the portions of the chassis contiguous with the back side edges 58 and 62 form the back section ears of the chassis.
- the respective front section ears of the chassis are secured to the respective back section ears of the chassis, along seal lines 66 by any suitable means, e.g., ultrasonic bonding, thermal bonding, adhesive bonding, etc., to form the undergarment shown in Fig. 1.
- the distance between the top front edge 46 and the middle of the crotch section 38, as defined by the transverse axis TX is less than the distance between the top rear edge 56 and the middle of the crotch section, since the front section 34 will have to cover less of the wearer's body than the rear section 36, i.e., the rear section has to cover the wearer's buttocks, whereas the front section only has to cover the wearer's belly and pubic area.
- the elastic fibers or threads 32 in the front section 34 extend parallel to each oilier and to the transverse axis TX from the top front edge 46 down the front section to a point in the crotch section adjacent, e.g., approximately 60 mm. from, the transverse axis TX.
- the elastic fibers or threads 32 in the rear section 36 extend parallel to each other and to the transverse axis TX from the top rear edge 56 down the rear section to a point in the crotch section adjacent, e.g., approximately 60 mm from, the transverse axis TX.
- the uppermost six or eight elastic threads 32 of the front and rear sections form what can be called the "waistband" 12 of the undergarment 10.
- the elastic threads of the waistband 12 can be the same gauge as the elastic threads making up the remainder of the chassis, although it is preferable that the elastic fibers forming the waistband are of a heavier gauge to provide a tighter fit at the waistband.
- the waistband portion may contain 6 - 8 elastic threads of 800 Decitex (DTEX) Lycra, whereas the remainder of the elastic threads of the chassis are 470 - 680 DTEX Lycra. While in the preferred embodiment shown, the spacing between all of the elastic threads is constant, e.g., 4 - 5 mm, that spacing can be different.
- the elastic threads of the chassis can be configured in a gradient spacing arrangement wherein the fibers at the top of the front and rear sections are spaced closer together than the fibers adjacent the transverse centerline (axis TX) to provide for a better fit for the wearer since it is desirable to have the closest fit to be at the waist.
- the spacing between the fibers from the waistband down to the transverse axis T can gradually increase.
- Fig. 2A is an illustration of the chassis shown in Fig. 2, wherein the elastic threads 32 are arranged in zones of decreasing tension or stretchability from the waistband 12 to the point of the chassis at which no longer includes such threads.
- the first or upper zone is the region of the chassis making up the waistband 12.
- the second or intermediate zone 14 is the region of the chassis from the waistband 12 to an intermediate point 16.
- the third or lower zone 1 is the region of the chassis from the intermediate point 16 to the point at which the elastic threads 32 end.
- the elastic threads 32 in the waistband 12 may exhibit a level of stretchability or tension of 250 - 300 percent.
- the threads in the middle zone 14 may exhibit a stretchability or tension of 175 - 250 percent and the threads in the lower zone 18 may exhibit a stretchability or tension of 125 - 175 percent. It must be pointed out that these ranges are merely exemplar ⁇ ' and otlier ranges can be implemented. In fact, instead of being three distinct zones of decreasing stretchability the elastic threads can be configured so that they exhibit a continuous decrease in stretchability from the waistband 12 until the point at which the elastic threads end.
- those threads be colored so that they can be visible through the nonwoven outer sheet 26. That color can be used to signify the intended user of the undergarment.
- men's undergarments may make use of blue colored elastic threads.
- Female undergarments may make use of lavender colored elastic threads.
- Unisex undergarments may make use of green elastic threads.
- the elastic threads making up the waistband in either the front section or the back section not be colored, i.e., be white. By so doing the user can readily determine the proper orientation for putting on the garment.
- the elastic bands making up the waistband 12 in the rear section of the undergarment are not colored, i.e., are white.
- the chassis 22 of this invention will exh ibit a much flatter and less puckered appearance than prior art undergarments that use far fewer and more largely spaced elastic threads. This not only provides a more aesthetically pleasing appearance for the garment, but also results in a garment which when worn is very concealable, e.g., simulating regular, cloth underwear.
- the undergarment includes respective leg openings or cuffs 44 for receipt of the legs of the wearer when the undergarment is w orn.
- the leg openings or cuffs 44 are elasticized so that they will engage the legs of the wearer to form a generally leak resistant interface therebetween .
- one preferred embodiment of this invention makes use of three elastic fibers or threads 68 for forming the leg cuffs in the front section 34 of the chassis and three elastic fibers or threads 70 for forming the leg cuffs in the rear section 36 of the chassis.
- the elastic threads 68 and 70 making up the leg cuffs are preferably of a gauge that is greater than the elastic fibers or threads 32.
- the elastic fibers 68 and 70 are of 800 DTEX Lycra.
- the three elastic fibers 68 making up the portion of the leg cuff 44 on the right side of the front section 34 of the chassis extend along and generally parallel to the marginal edge of the cut-out recess 40 on the right side of the chassis from the linear side edge 48 to the transverse axis TX. From that point the leg cuff fibers 68 extend in a concave arc section 72 across the chassis, whereupon the leg cuff fibers 68 extend upward along and generally parallel to the marginal edge of the cut-out recess 42 on the left side of the front section of the chassis up to the linear left side edge 52.
- the three leg cuff fibers 68 are arranged in a generally V-shaped configuration.
- the elastic fibers 70 making up the portion of the leg cuff on the right side of the rear section 36 of the chassis extend along and generally parallel to the marginal edge of the cut-out recess 40 from the linear rear side edge 58 to the transverse axis TX. From that point the leg cuff fibers 70 extend in a concave arc section 74 across the chassis, whereupon the leg cuff fibers 70 extend downward along and generally parallel to the marginal edge of the cut-out recess 43 on the left side of the rear section up to the linear left side edge 62.
- the three leg cuff fibers 70 forming the portion of the leg cuffs in the rear section 36 of the chassis are arranged in a generally V-shaped configuration, albeit slightly different in shape to the leg cuff fibers in the front section of the chassis.
- That concave pocket provides a better and more aesthetically pleasing and comfortable fit, while enhancing concealment of the undergarment when it is worn under outer clothing.
- the portions of the elastic cuff fibers 68 and 70 forming the arc shaped sections 72 and 74 are not continuous, but rather are sectioned so that there are gaps in those fibers as shown in Figs. 2 and 5.
- the absorbent core assembly 24 is a generally thin elongated, e.g., rectangular, body (e.g., approximately 16 to 22 inches long and approximately 5 inches wide, depending upon the size of the chassis in which it will be used).
- the absorbent core assembly is fixedly secured between the inner sheet 28 of the chassis and a core assembly cover sheet 76 (Figs. 4 and 5).
- the core assembly cover sheet 76 is located closest to the body of the wearer and is made up of a nonwoven material like the outer or inner sheets 26 and 28, respectively, and is larger in length and width than tlie core assembly 24.
- the long side marginal edges 77 of the cover sheet 76 are folded over themselves to form marginal flaps 79 (Fig. 2).
- a plurality, e.g., three, longitudinally extending elastic threads or fibers 82 are disposed between each marginal flap 79 and the immediately adjacent underlying portions of the cover sheet 76.
- the portions of the marginal flaps 79 that are adjacent each end of the cover sheet 76 are adhesively secured to the outer surface of the underlying portions of the cover sheet, with the elastic threads 82 being adhesively secured within the folded over marginal flaps 77.
- the elastic threads 82 extend parallel to each other and to the folded edges of the marginal flaps 79.
- the same adhesive that is used to secure the inner and outer sheets 26 and 28, respectively, together is used to adhesively secure the marginal flaps and the elastic threads 82 in place.
- the intermediate portions of the marginal flaps, i.e., the portions of the marginal flaps between the ends of the cover sheet 76, are not adhesively secured to the outer surface of the cover sheet so that they will form stand-up leg barriers or gathers 106, as will be described later.
- the undersurface of the cover sheet 76 is adhesively secured about the periphery thereof to the inner sheet 28 of the chassis 22 by an adhesive, e.g., tlie same adhesive as used to secure the inner and outer sheets 26 and 28, respectively, together.
- a liquid impervious barrier sheet 78 is interposed and secured between the core assembly 24 and the inner sheet 28 of the chassis as also seen in Figs. 4 and 5.
- the barrier sheet 78 may be formed of any suitable material, e.g., a film of polypropylene, polyethylene, or polyester.
- the barrier sheet 78 being liquid impervious, prevents any liquid in the core assembly from leaking out of the core and passing through or wetting the chassis.
- the core assembly 24 is centered about a longitudinal central axis LX, but not centered with respect to the transverse axis TX.
- One end of the core assembly is located in the front section 34 of the chassis, a middle portion of the core is located in the crotch section 38, and the oilier end of the core is located in tlie rear section 36.
- one end of tl e core is located in the front section at or just below the right and left side edges 48 and 52, respectively.
- the opposite end of the core assembly is located in the rear section 36 at or just below the right and left side edges 58 and 62, respectively, whereupon more of the core is located in the rear section of the chassis than is located in the front section of the chassis.
- the portions of the elastic threads 32 which are located in the areas of the chassis where portions of the absorbent core assembly 24 are located are discontinuous or segmented, i.e., they are cut into separated segments so that there are gaps 80 between immediately adjacent segments of each elastic thread. As such those elastic thread segments will not tend to collapse or buckle the core assembly, thereby contributing to the concealability, aesthetics and comfort of the undergarment
- the portions of the elastic filaments located outside of the bounds of the core assembly in the back section are not discontinuous to form what can be called "cheek" regions of the chassis that will closely conform to the buttocks of the wearer when the undergarment is worn.
- the elastic threads 32 located at the core assembly are cut or segmented on a 45 degree bias to create the gaps 80. That bias cut has the effect of creating a somewhat more aesthetically pleasing pattern of broken thread segments than if the elastic threads 32 were cut parallel to the central longitudinal axis LX, since any misalignment of longitudinally cut segments would be readily percei vable and give the appearance of a product that is haphazard.
- the undergarment 10 includes a pair of upstanding stand-up elasticized leg barriers or gathers 106.
- Those leg barriers or gathers are conventional in that they extend upward from the undergarment at the top of the core assembly and form a fence along either side of the core assembly.
- the leg barriers or gathers 106 work in conjunction with the elastic leg cuffs 68 and 70 to prevent leakage of the insult out of the leg openings 44.
- the leg barriers or gathers 106 are formed by two sets of three elastic threads or fibers 82 (Fig. 2) which are adhesively secured to the core assembly cover sheet 76 closely adjacent the side edges 77 thereof.
- Each of the elastic fibers 82 extends the full length of the cover sheet 76. The tension applied by those fibers or threads tend to cause the intermediate portions of the core assembly cover sheet 76 to stand up from the core assembly when the garment is in the condition like shown in Fig. 1, i.e., ready to be worn.
- the core assembly is designed to absorb liquids that in some way come out of or exit the body of an adult. While the core assembly 24 has particular utility to be used as a component of an undergarment, e.g., a protective disposable brief, it may be used in other applications.
- the absorbent core assembly 24 is a generally planar body of any suitable peripheral shape.
- the core assembly 24 is an elongate rectangle. It has a longitudinal axis which is parallel to the longitudinal axis LX and a transverse axis which is parallel to the transverse axis TX.
- the exemplary embodiment of the core assembly is clearly shown in Figs. 4, 5 and 1 1 and basically comprises a first or top absorbent section 84, a fluid transfer or wicking layer 86, and a second or bottom absorbent section 88.
- a fluid acquisition layer 85 like those of prior art absorbent undergarments is located between the core assembly cover sheet 76 and the first absorbent section 84.
- the acquisition layer 85 serves to move the liquid to be absorbed linearly across its area to spread it out across the core assembly.
- a fluid acquisition layer that can be used in this invention is through air bonded ADL 40 GSM (grams per square meter) which is 12.1 cm. wide.
- Other materials can be used for the fluid acquisition layer.
- Shalag ST6CT8H50, STAPPEL40 ADL, STA1PBL40 or STA2PBL38m sold by Shalag US, Inc. or a similar material produced by WPT Corporation or other suppliers of similar ADL nonwoven materials.
- Such a material is identified by the vendor as being 40 GSM basis weight 300% Polyester White.
- the fluid acquisition layer is preferably coextensive in size and shape to the first absorbent section 84.
- the first or top absorbent section 84 is of elongated rectangular shape and is provided to move the liquid linearly and is in the form of at least one, and preferably two or more quilted layers.
- the first absorbent section 84 is made up of two quilted iayers, namely a first layer 90 and a second layer 92 (shown in Figs. 7 and 8, respectively). Each of those iayers is in the form of a pair of non-woven sheets which are fixedly secured together along intersecting seal or embossed lines 94 to form a plurality of diamond shaped enclosed pockets 96 between the intersecting embossed lines.
- the first layer 90 of the first absorbent section 84 is in the form of a plurality of first pockets 96
- the second layer 92 is in the form of a plurality of first pockets 96.
- the seal lines 94 can be made by any suitable technique, e.g., ultrasonic welding, thermal welding, adhesive securement, etc.
- Each first pocket 96 is of a square shape, e.g., approximately 1.5 cm. by 1.5 cm., with the width of each of the intersecting seal lines being approximately 1 mm. If desired, the first pockets can be larger in size, e.g., up to 3.0 cm by 3.0 cm. or more.
- the first pockets 96 are oriented so that two of their diametrically opposed comers extend parallel to the longitudinal axis of the core assembly 24, while the other two diametrically opposed corners extend transverse or perpendicular to that axis. Each pocket is partially filled with free SAP, as will be described later.
- the orientation of the pockets with respect to the longitudinal axis establishes a tortuous flow path for fluid along the longitudinal axis of the core.
- the quilted nature of the two layers 90 and 92 of first section 84 renders the free SAP particles of the layers of that section resistant to migration with respect to the core assembly and thus obviates the need for adhesives to bond to the SAP particles to prevent their migration .
- Hie nonwoven sheets making up the two layers of the first absorbent section can be a non-woven, liquid pervious material, e.g., 15 +/- 5 GSM basis weight hydrophilic spun bond nonwoven polypropylene or the like that is 12.1 cm wide.
- a non-woven, liquid pervious material e.g., 15 +/- 5 GSM basis weight hydrophilic spun bond nonwoven polypropylene or the like that is 12.1 cm wide.
- One particularly suitable nonwoven is available from PGI Nonwovens under code # B0305 white SBPP hydrophilic polypropylene spunbond.
- the upper body side layer is hydrophilic where the bottom layer may be similar for ease of manufacturing. Alternatively, it could be hydrophobic or a barrier film.
- Each of the first pockets 96 of the layers 90 and 92 of the first absorbent section 84 contains a free, high capacity, but slow absorbing SAP 98, with each first pocket being filled to less than half of its volume or capacity, as indicated by the broken lines in the pockets shown in Figs. 7 and 8, and preferably within the range of approximately 25 to 35 percent of its volume or capacity.
- the amount or volume of SAP 98 in at least some of the first pockets 96 of the first layer 90 is within the range of approximately 25 to 35 percent of the volume or capacity of those first pockets.
- the amount or volume of SAP 98 in at least some of the first pockets 96 of the second layer is within the range of approximately 80 to 120 percent of the amount or volume of the SAP 98 in the first pockets of the first layer and within 25 - 35 percent of the volume or capacity of the first pockets of the second layer.
- each pocket 96 encapsulates approximately 0.02 to 0.05 grams of SAP, or approximately 100 to 196 grams of SAP per square meter.
- the partial filling of the pockets with the high capacity, but slow absorbing SAP 98 serves to allow for the expansion and swelling of the SAP when in contact with the liquid to be absorbed, e.g., urine.
- the pockets 96 were filled with significantly more SAP 98, such as greater than 0.10 grams per pocket, the SAP would be constrained in its ability to swell and thus unable to absorb additional fluid. In some instances it may be appropriate to underfill the pockets employing 0.03 grams or even 0.02 grams to ensure maximum utilization at a slightly reduced capacity. It should be pointed out that other size pockets than those described above are contemplated. For example, one can increase the amount of SAP 98 per pocket by employing larger pockets. In each case, the ratio of SAP to the pocket size preferably should not exceed approximately 0.44 grams per 1 square cm . per pocket. If larger pockets are contemplated, then the same ratio of weight per unit area should be applied.
- the vortex time of the high capacity, but slow absorbing SAP 98 be relatively high, e.g., approximately 30 to 90 seconds or more to ensure that all of the liquid voided by the user is absorbed in that section of the core assembly as will be described later.
- SAP 98 can be BASF T-9900 available from BASF Corporation, or any other suitable SAP.
- the two layers 90 and 92 of first absorbent section 84 can have one or two layers of a nonwoven interposed between the layers 90 and 92. The use of such a layer of layers of nonwoven interposed between the layers 90 and 92 should serve to increase the void space to allow for faster fluid flow into more pockets and layers.
- the fluid transfer or wicking layer 86 is best seen in Fig. 9 and serves to aid in transporting voided liquid by wicking or the like, in particular the layer 86 is configured to aid in allowing the liquid to linearly wick along the longitudinal axis LX so that it assists in moving the liquid to be absorbed, e.g., urine, from the central middle area of the core where the liquid is first insulted to the ends of the core where that liquid may not fully reach and to allow that liquid to pass through it into the second absorbent section 88.
- the wicking layer is an airlaid tissue approximately 100 GSM.
- the wicking layer has a corduroy or corrugated embossing pattern that is employed to further assist wicking.
- the corrugations or corduroy pattern is formed by a plurality of closely disposed parallel seal lines 104 made by any suitable technique, e.g., ultrasonic welding, thermal welding, adhesive securement, etc.
- the wicking layer is also of an elongated rectangular shape, but preferably of a narrower width, e.g., approximately 5.1 cm wide, than the first and second sections 84 and 88, respectively, for reasons to be described later.
- the wicking layer is not bonded, also for a reason to be described later.
- the wicking layer may be in the form of plural layers to provide the desired wicking properties.
- the wicking layer may also have visible holes, of 5 mm in size or larger, added to further enhance fluid pass-through.
- the second or bottom absorbent section 88 is preferably coextensive in size and shape to the first or top absorbent section 84 and is configured to be disposed away from the wearer when the undergarment is worn.
- the second absorbent section 88 is constructed somewhat similarly to the first absorbent section 84, but is in the form of a single quilted layer.
- That layer is formed in the same manner as each of the layers of the first absorbent section, i.e., it comprises a pair of non-woven sheets of the same material as the sheets of the fi rst absorbent section and which are fixedly secured together along intersecting seal or embossed lines 94 to form a plurality of diamond shaped enclosed second pockets 96 between the intersecting embossed lines like the pockets 96 of the first absorbent section 84.
- the second pockets 96 of the second absorbent section 88 can be of the same size as the first pockets of the first absorbent section, e.g., 1.5 - 3.0 cm. square, or may be of a different size, e.g., smaller, than the first pockets of the first absorbent section 84, but still within that range, to permit greater expansion of the high fluid absorption capacity of the SAP 98.
- Each of the second pockets 96 of the second absorbent section 88 is partially tilled with a free, fast acting but lower absorption capacity SAP 100.
- each second pocket is filled to less than half of its volume or capacity, and preferably within the range of approximately 20 - 30% of its volume or capacity.
- the vortex time of the fast acting but lower absorption capacity SAP 100 is much quicker than the vortex time of the slow acting but high absorbency SAP 98.
- the SAP 100 may have a vortex time in the range of approximately 3 - 20 seconds.
- the ratio of the vortex time of the slow acting SAP 98 of the first absorbent section to the fast acting SAP 100 of the second absorbent section should be anywhere in the range of approximately 6: 1 to 3 : 1, with the higher ratio being preferred.
- one preferred vortex time for the SAP 98 is at least 60 seconds, with the vortex time for the fast acting SAP to be 10 seconds or less.
- the fast acting SAP 100 can be Aqua Keep type BA40B available from Sumitomo Seika Chemicals Co., Ltd., or the like. That product has a very fast vortex time, e.g., approximately 3 to 10 seconds.
- the quilting of the second section renders the SAP of the second absorbent section resistant to migration with respect to the core assembly without requiring adhesives to bond to the superabsorbent particles to prevent their movement or migration.
- Each pocket 96 of the second absorbent section 88 encapsulates approximately 0.02 to 0.04 gm of the SAP, or approximately 150 GSM. Since the pockets are only partially filled, they like the pockets of the first absorbent section 84, to allow for the expansion and swelling of the superabsorbent polymers when in contact with the fluid. If the pockets 96 of the second section were filled with significantly more SAP, such as greater than 0.06 gm per pocket, the SAP particles would be constrained in their ability to swell and thus unable to absorb additional fluid. However, other size pockets may be contemplated to increase the amount of SAP per pocket by employing larger pockets. In each case, the ratio of SAP 100 to the pocket size preferably should not exceed approximately 0.16 gm per 1 square cm per pocket. If larger pockets are contemplated, then the same ratio of weight per unit area should be applied.
- the fast acting SAP 100 may have a tendency to shatter somewhat during the processing and formation of the section 88.
- a lubricant such as mineral oil can be added to the SAP 100, the mineral oil being in the range 0.1% to 5%: and preferably 0.1 to 1.0%.
- the inherent nature of SAP 100 of the bottom section allows one to add some of the slower acting SAP 98 like in the first section 84 to fast acting SAP 100 in the second or bottom section to minimize or prevent gel blocking up to 20%.
- the nonwoven material making up the bottom sheet of the quilted second section 88 on may by colorized or printed on bottom by adding an SMS or nonwoven or poly or pigmented specs to SAP for the purpose of indicating the bottom of the absorbent core assembly from the top. This is to eliminate the possibility of reversing the absorbent structure, which would result in a non-functional absorbent core.
- the layers 90 and 92 of the first section 84, and the single layer of the second section 88 of the core assembly are fixedly secured together along their marginal (longitudinal) edges by respective seal lines, with the wicking layer interposed between the first and second sections to form a composite core assembly.
- seal lines can be formed by any suitable technique, e.g., ultrasonic welding, thermal welding, adhesive securement, etc. The most desirable process is to ultrasonically bond the components together with a 2 mm, wide intermittent bond pattern running down the sides of the composite core assembly and spaced about one cm. from each edge, e.g., somewhat like a railroad track with approximately four bond points or bars per cm.
- the wicking layer 86 is narrower than the first and second sections assists in bonding the components of the core assembly together. Moreover, being narrower, the wicking layer 86 enables fluid voided by the person wearing the undergarment 10 to spill over the side edges onto the underlying second absorbent section, thereby facilitating fluid transfer to that section.
- the absorbent core assembly 24 With the absorbent core assembly 24 located in the undergarment, when the undergarment is worn the absorbent core assembly forms a body-facing side of the undergarment confronting the perineum region of the wearer.
- that urine flows into the first absorbent section 84 to the fast acting SAP 98 located in the pockets 96 of the top layer 90 of that section, from whence it flows into the bottom layer 92 of that section and through that layer.
- the SAP 98 in the top section 84 is slow acting, the voided urine quickly flows out of the top section 84 into the underlying wicking layer 86, whereupon it is dispersed across the area of the wicking layer, through it and over its marginal edges to the underlying second absorbent section 88.
- the wicking layer 86 also serves to enhance the fluid transfer from the lower faster absorbent second absorbent section 88 into the upper slower first absorbent section 84.
- the embossed pockets of the first and second absorbent sections are not aligned directly with respect to each other. Rather, they are offset in a direction parallel to the longitudinal axis LX and/or in a direction parallel to the transverse axis TX or in directions parallel to both the longitudinal axis and the transverse axis. This allows for improved fluid migration not only in the longitudinal and transverse directions, but also in a direction perpendicular to the plane of the core assembly.
- Figs. 12 - 17 there is shown an alternative embodiment of the core assembly 124 wherein the pockets of the first and second sections are not coincident, but rather are offset from each other.
- the core assembly 124 offers some advantages from the standpoint of facilitating fluid movement through it, in the interest of ease and simplicity of manufacturing the core assembly, reduced capital costs and concomitant consumer savings, the embossed pockets of the first and second may be directly aligned under each layer and under each other like the core assembly 24.
- the quilted construct of the core assemblies of this invention functions via what can be called a ''compartment spill over phenomena".
- the liquid to be absorbed when brought to the each section of the core will fill up the SAP contained in a compartment (pocket) of that section, whereupon the compartment and the SAP in it will swell.
- the SAP in that compartment is fully utilized (e.g., has swelled to its maximum)
- the liquid then ''spills over" to the adjacent compartments.
- the ultrasonicaily formed diamond shaped pockets or compartments 96 of the first absorbent section and the second absorbent section have approximately a 1 mm space between them as a result of the width of their respective intersecting fixedly secured seal lines 94.
- the wicking layer 86 also enhances liquid movement as does the unaligned nature of the compartments or pockets.
- the addition of a topmost body side acquisition layer 85 further aids fluid transfer to assist fluid in the spill over from one SAP containing compartment or pocket to the next.
- the core assembly 24 can use less SAP 98 in each of the pockets 96 of the first section than would be used if the first section included only a single quilted layer. As such, with less SAP 98 in a given pocket there is sufficient room for the SAP 98 to expand in the pockets so that it can be fully utilized to desorb the SAP from the second absorbent section. While it is desirable to use the least amount of SAP in the pockets of the first absorbent section for economic reasons, the amount used must be able to be fully utilized to achieve the desired absorption rate and capacity.
- the SAP 98 in each of the two layers 90 and 92 of the first absorbent section is within the aforementioned desired range of pocket fullness and that the SAP has a vortex time of in the range of 30 - 90 seconds to be able to fully desorb the liquid from the second absorbent section.
- that configuration maximizes SAP performance and enables efficient and effective transfer of liquid introduced into the core assembly through each of the two layers of the first absorbent section into the second absorbent section, without any tendency for the SAP 98 of the first absorbent section to impede the flow of liquid into the second absorbent section as could result from "gel blocking".
- gel blocking occurs when the surface of the SAP in a section that comes into contact with the liquid first swells and blocks the lower levels of SAP of that section from fully absorbing to their maximum capacity. By using less SAP in each pocket, but by using more pockets via the two layer construction of the fi rst absorbent section, the occurrence of gel blocking is minimized, if not eliminated. Tims, the liquid introduced into the core assembly can quickly pass through the first absorbent section to be wicked into the second absorbent section, where it is quickly absorbed by the SAP of the second absorbent section, and from whence that liquid can go back to the first absorbent section where that liquid is slowly absorbed, thereby desorbing the second absorbent section, so that all of the liquid is trapped in the core assembly to keep the wearer dry.
- the first absorbent section may include three quilted layers, each of the three quilted layers being constructed similarly to the two quilted layers 90 and 92 described above. That alternative embodiment of the core assembly is shown in Fig. 18 and is designated by the reference number 224.
- the core assembly 224 is similar to the construction of the core assembly 124 shown in Fig. 17, except that the first absorbent section 184 includes three quilted layers.
- the first section 84 includes a first layer 90, a second layer 92, and a third layer 93.
- the third layer 93 is constructed similarly to the layers 90 and 92 and is also partially filled with a slow acting high absorbency SAP 98, wherein the volume or amount of SAP 98 in at least some of the first pockets of the third layer 93 is within the range of approximately 80 - 120 percent of the volume or amount of SAP 98 in the first pockets of the second layer 92 and within the range of approximately 25 - 35 percent of the volume or capacity of the first pockets of the third layer 93.
- the core assemblies as described heretofore make use of the same amounts of SAP in the pockets of each layer of the first absorbent section. That is merely exemplary.
- the core assembly may be constructed to have stripes or zones of pockets with higher and lower concentrations of the slow acting, but high absorbency SAP 98 in a layer of the first absorbent section 84, with higher concentrations adjacent the long side marginal edges. Such an arrangement should deter the leakage of liquid out the sides of the core assembly and is shown in Fig. 19. In particular, in Fig.
- the pockets located adjacent the long side marginal edges of the core assembly which are designated as 96A, and which are shown shaded by closely spaced vertical lines are filled with a higher concentration or amount of the SAP 98 than the pockets located between the pockets 96A.
- the pockets filled with less SAP are designated by the reference number 96B.
- the pockets 96A form two stripes or zones extending along the marginal edges of the core assembly.
- Each stripe of the higher concentration of SAP 98 is preferably approximately 1/3 the width of the core assembly. That is merely exemplary and the stripes making up the higher concentration and lower concentration of SAP 98 can be of different widths.
- the amount of SAP 98 within the pockets 96A and 96B should still be within the ranges as discussed earlier.
- the core assembly is constructed like the core assembly of Fig. 17 it is preferred that the layer making use of the stripes or zones of different concentrations of the SAP 98 will be in the second layer 92.
- the core assembly making use of a layer of stripes or zones of different concentrations of the SAP 98 is constructed like the embodiment of Fig. 19 the striped or zoned pockets of higher and lower concentration could be in either or both of the second layer 92 and the third layer 93, but preferably be in the second layer 92.
- the first or upper layer 90 should not include stripes or zones of higher and lower concentrations of the SAP 98 since that layer faces the body and hence should be kept as dry as possible.
- the use of a layer of different concentrations of SAP 98 in the first absorbent section should not deter the transfer of the liquid insult, e.g., the urine voided, quickly through the first absorbent section into the second absorbent section, since the SAP 98 in the first absorbent section does not absorb liquid quickly.
- the subject invention can use less expensive inorganic additives to maximize SAP performance. Since the goal of the assembly core of this invention is to allow all the SAP particles of each section to achieve their maximum absorbent capacity, inorganic additives such as high porosity Zeolites, Upsalite, microspheres or other inorganic materials that do not swell or add to the gel blocking phenomena may be included with the SAP of the core.
- inorganic additives such as high porosity Zeolites, Upsalite, microspheres or other inorganic materials that do not swell or add to the gel blocking phenomena may be included with the SAP of the core.
- Another approach in lieu of the use of such inorganic additives, or an additional approach to using such additives, is to utilize an acquisition layer, such as a 40 gm Shalag ADL or similar materials from Shalag US, Inc. or similar materials available from WPT Corporation or others may be disposed underneath the second absorbent section of the core.
- a second wicking layer could be added between the first and second absorbent layers, if
- the fast acting S AP 100 of the second absorbent section has a very rapid vortex time, in some cases, and it may have a tendency to gel block, particularly those particles of SAP 100 located closest to the surface of the body of SAP particles within a pocket as opposed to those particles of SAP 100 located in the interior of that body of SAP. In such a case, those interior particles of SAP 100 may not have a chance to absorb the fluid insult.
- a "caking inhibitor” or ' " flow agent” may be added in the pockets containing the fast SAP 100 and blended with the SAP in those pockets.
- the caking inhibitor or flow agent can take the fonn of calcium sulfate, magnesium carbonate, diatomaceous earth, kaolin, calcium silicate, or the like.
- the caking inhibitor or flow agent may make up 5 to 20% of the volume of the S AP 100 within the pocket and should preferably have a similar or larger particle size than particles of the SAP 100.
- the SAP 100 has a distribution in microns of less than 1 1% belo 250 microns, approximately 73% between 250 and 500 microns and approximately 16% greater than 500 microns with none greater than 850 microns.
- the anti-caking agent should have a particle size of greater than 250 microns, but probably less than 850 microns.
- the Zeolite odor reducing agent Since a Zeolite odor reducing agent will be located within pockets 96 in which the high capacity SAP 98 is located, that SAP will desorb moisture from the Zeolite and thus allow it to function to reduce odors over an extended period of time. In the interest of keeping the wearer of the undergarment 10 dry, it is preferred that the Zeolite odor reducing agent is not located in the layer 90 since that layer is located closest to wearer when the undergarment 10 is worn. Thus, if the first absorbent section of the core assembly includes two quilted layers 90 and 92, like that of Fig. 17, the Zeolite odor reducing agent should be located in the layer 92. If the first absorbent section of the core assembly includes three quilted layers 90, 92, and 93, like that of Fig. 18, the Zeolite odor reducing agent should be located in either or both of the layer 92 and 93, although it is preferred that it be located in the layer 92.
- absorbent core assemblies constructed in accordance with this invention could be used in lieu of an absorbent core that is employed in current existing absorbent products.
- absorbent core assemblies constructed in accordance with this invention can be used in adult incontinence products (e.g., briefs, panties, pads, etc.), infant absorbent garments (e.g., diapers), sanitary napkins, a feminine napkins, panty liners, or any other product arranged to be worn by a being to absorb liquids from the being.
- the pockets 96 of the two sections 84 and 88 of the core assembly are shown as being diamond shaped, with all of the pockets being the same size that is merely exemplar '.
- each of the pockets is hollow and is partially filled with SAP.
- the SAP may be in the form of particles or fibers or any other form of SAP which is free or unsecured.
- Hie pockets serve to hold the SAP therein to prevent migration of the SAP through the core. It is, however, contemplated that for some applications an adhesive could be used in the pockets to thereby hold the SAP in place. That alternative configuration provides an additional means, in addition to the pockets, for preventing the SAP from migrating through the core.
- FIGs. 20 - 27 details of various methods in accordance with this invention will be described for making the exemplary absorbent undergarment and the exemplary absorbent core assembly described above.
- One method, which is perhaps the simplest, for producing the absorbent core assembly 24 is shown in the block diagram of Fig, 20. That method basically comprises forming the top or first section 84 of the core 24, as designated by the block 200. The manner of forming that section of the core will be described with reference to Fig. 21.
- the bottom, or second section 88 of the core 24 is formed in accordance with block 202, with the specific ma ner of forming that section described with reference to Fig. 22.
- the assembly of the first section 84 and second section 88 to form the absorbent core assembly 24 is designated by the block 204, and the details of forming it will be described with reference to Fig. 23.
- a first layer or web of approximately 15 +/- 5 GSM polypropylene spunbond nonwoven material or the like is provided as shown in block 210.
- the first layer or web is unwound from a reel 300 of such material, and the slow acting but high capacity SAP 98 is applied, e.g., sprinkled, onto this web material from a powder feeder 302 at a rate of approximately 100 to 200 grams per square meter (GSM) as set forth in block 212. Lesser or greater amounts of SAP may be applied as the product design warrants.
- GSM grams per square meter
- a second iayer or web of similar nonwoven material is provided as set forth in block 214.
- the first section 84 and the second section 88 are assembled to form the absorbent core assembly 24 as set forth in block 204 of Fig, 23 and in Fig. 26.
- a web of a fluid transfer or wicking layer 86 e.g., a corrugated airlaid tissue of approximately 100 GSM, is provided, as set forth in block 240.
- the web 86 is unwound from a reel 342 and passed over a roller 344, under another roller 346, whereupon it is disposed over the quilted layer forming the second section 88.
- a fluid acquisition layer 85 is disposed over the absorbent core assembly 24, if the product in which the absorbent core assembly is to be used needs such an acquisition layer.
- a fluid acquisition layer is provided in the exemplar ⁇ ' embodiment of the absorbent undergarment or brief 20, a fluid acquisition layer is provided.
- the top or first section 84 of the composite absorbent core may include only a single quilted layer containing the SAP 98.
- the first section 84 may include more than two layers, which may be produced in a like manner as described above to increase the total absorption capacity and performance attributes.
- additional layers of the slower absorbing, but higher capacity SAP may be added.
- the composite absorbent core contains only one layer of the faster absorbing, but lower capacity SAP in the layer furthest from the body.
- Fast absorbing SAP tends to exhibit the phenomena of gel-blocking. That is the outer SAP particles absorb and swell, but block further fluid migration into the inner layer of the same SAP particles.
- the construction of the composite absorbent cores of this invention overcomes this gel-blocking phenomena by under-filling the absorbent pockets to ensure that ail the SAP has exposure to the fluid. Utilizing a second layer of this fast acting, but gel-blocking prone SAP on top of the first layer may limit fluid pass through to the bottom layer further away from the body layer.
- narrower layers of alternative materials may be inserted between the layers and betw een the tacking bonds.
- materials include: airlaids composed of compressed fluff pulp and or pulp/SAP, cotton containing webs, un-fiberized pulp rolls, or other similar wicking materials may be added between the layers to enhance fluid migration to the ends.
- Other materials such as thru air bonded carded webs, 3D perforated film, spun-lace and the like may be incorporated instead to assist in fluid migration through the layers, rather than directly absorbing fluids themselves.
- full width materials may be inserted between the layers.
- the methods of forming the composite absorbent core as just described are preferably accomplished on a production converting line in which an indeterminate length web of the first or top section 84 is assembled as described above, an indeterminate length web of the second or bottom section 88 is assembled as described above, and both of those webs are provided along with an indeterminate length of the wicking layer 86 so that all of those webs/ ayers can joined together to form a continuous web which can be processed, e.g., cut, to form a series of composite core assemblies.
- T ms the precursor web of composite absorbent cores as described above is suitable to be ran on and through the converting production line as a substitute for the prior pulp/SAP absorbent structures used previously on such production lines.
- a web of a cloth-like, nonwoven breathable fabric e.g., spunmelt polypropylene, or spunmelt polyethylene, or spunmelt polyester
- a series of sheets or shells 26 Each of those sheets 26 has the profile like that shown in Fig. 2 and 2A and forms the outer sheet of the absorbent undergarment or bnef 20 as set forth in block 252.
- the outer sheet is preferably laminated to a barrier film like material to be liquid impermeable as set forth in block 254.
- a web of a cioth-like, nonwoven breathable fabric e.g., spunmeit polypropylene, or spunmeit polyethylene, or spunmeit polyester, is cut sequentially to form a series of sheets or shells 28, Each of those sheets 28 has the same profile as the sheets 26 and forms the inner sheet of the absorbent undergarment or brief 20.
- the sheets 28 are superimposed over the sheets 26, whereupon the two sheets are joined together to fonn a sandwich with the elastic fibers 32, 68 and 70 interposed and held in place between those sheets as set forth in block 262.
- a calibrated rotating cutter is brought into engagement with each sandwich in selected regions of the sandwich where the composite absorbent core 24 will be located.
- the calibrated rotating cutter applies sufficient force to break the closely spaced elastic fibers in those regions of each sandwich into plural segments with gaps 80 between the segments as set forth in block 262 without damaging the sheets 26 and 28. That action completes the series of chassis.
- the SAP pocketed layers forming the absorbent core assembly may be constructed in widths wider than the desired final absorbent core assembly width utilized in the absorbent undergarment.
- a one, two, three or more-meter-wide machine can unwind a layer of nonwoven, have SAP applied as described above, a top layer then maybe added and then the entire web embossed to form ultrasonically bonded pockets partially filled with SAP.
- This wide web material further may be ultrasonically slit into multiple layers and edge bonded with an ultrasonic slitter bonder or the like such that the edges are slit and bonded at the same time. This action produces multiple slits of the desired width for the final product, resulting in a process that is substantially more efficient, lower in cost with the same quality as a one-at-a-time individually formed SAP filled pocketed absorbent layer.
- each absorbent layer may be created on a single pass or a single layer machine. Then the SAP and/or the amount of SAP may be changed, encapsulating material layers changed, embossing roll pocket pattern changed and optimized for the desired absorbent product construction.
- Another method contemplated by this invention is to use an integral or unitary web including quilted longitudinally extending parallel stripes defining the quilted layers 90, 92 and 88 and to fold that unitary web into a generally " 'G' 1 shaped cross-section, like shown in Fig. 28, wherein the stripe defining the quilted layer 90 overlies the quilted layer 92, which in turn overlies the quilted layer 88, in lieu of the use of three separate quilted layers 90, 92 and 88 and then securing them together as described above.
- the system for carrying out such an alternative method is shown in Fig. 26.
- the width of the material on that reel is equal to the aggregate widths of the webs 90, 92 and 88.
- This triple wide web material 402 is fed under three SAP powder feeders 404, 406, and 408.
- the powder feeder 404 is configured to sprinkle or spray the high absorbency, slow acting SAP 98 in a stripe 410 on the top surface of the w eb 402 and in the area which makes up one third of the width of the web 404 and which is contiguous with one side edge of that web.
- the powder feeder 406 is configured to sprinkle or spray the high absorbency, slow acting SAP 98 in a stripe 412 on the top surface of the web 402 and in the area which makes up one third of the width of the web 404 and which is contiguous with the opposite side edge of the web 402.
- the powder feeder 408 is configured to sprinkle or spray the low absorbency, fast acting SAP 100 in a stripe 414 on the top surface of the web 402 and in the area which makes up the middle third of the width of the web 404 between the stripes 410 and 412.
- Another reel 416 holding a roll of a web 418, which is identical to the web 402, is provided.
- That web 418 is unwound so that it extends and is disposed over the web 402 downstream of the region where the stripes 410, 412 and 414 of the web 402 have had the SAP sprinkled or sprayed thereon.
- the two webs 402 and 418 are then fed to a sealing station 420 which preferably is in the form of an ultrasonic roller. That roller seals the webs together to form the diamond shaped pockets in which the SAP is located.
- the stripe 410 of the web 402 with the superimposed portion of the web 418 is sealed together by the sealing station 420 to form the quilted layer 92 with its diamond shaped pockets being partially filled with free SAP 98.
- the stripe 412 of the web 402, with the superimposed portion of the web 418 is sealed together by the sealing station 420 to form the quilted layer 90 with its diamond shaped pockets being partially tilled with free SAP 98.
- the stripe 414 of the web 402, with the superimposed portion of the web 418 is sealed together by the sealing station 420 to form the quilted layer 88 with its diamond shaped pockets being partially filled with free SAP 100.
- the sealing station 420 also seals the webs longitudinally so that the portion of the web forming the quilted layer 92 is sealed and isolated from the portion of the web forming the quilted layer 88, and the portion of the web which forms the quilted layer 90 is sealed and isolated from the portion of the web forming the quilted layer 88.
- the composite web which exits the sealing station 420 then passes over a folding table 422, where the composite web is folded into the generally G-shaped cross sectional shape shown in Fig. 28.
- the portion of the composite web exiting the sealing station that forms the quilted layer 92 is folded over the composite web portion forming the quilted layer 88, and the composite web portion forming the quilted layer 90 is folded over the composite web portion forming the quilted layer 92.
- a second material may be added between the folded over portions.
- the absorbent core assembly is to include the heretofore identified wicking layer 86, a web of the material making that layer can be inserted between the layer 88 and the layer 92.
- the assembled composite web exiting the folding table 422 is provided to a tacking bonder unit 424 including an ultrasonic roller for sealing the marginal edges of the composite web.
- the edge sealed composite web exiting the bonding unit 424 can then be rolled up on a reel 426 for subsequent use.
- the multi-layer machine should include at least two or more superabsorbent feeding systems, multiple bonding layer unwind stations, embossing rolls, ultrasonic bonding equipment, slitters, bonders and winders for the finished composite absorbent core.
- the machine would need to unwind a layer of nonwoven barrier like material or film, apply the SAP, have a second layer of permeable bondable fabric applied on top and then bond to form a quilted layer having pockets partially filled with SAP.
- a similar application would be carried out subsequently after the first stage. In that second stage operation a permeable nonwoven is unwound into the bottom layer of that process, SAP is applied to that bottom layer and another bonding layer is incorporated on top and subsequently bonded, again creating a quilted layer of partially filled pockets of SAP.
- a third or additional layers can be produced in the same manner. Again, subsequently bonded and slit to size at the winding up the final absorbent core area of the process.
- an additional unwind station may be added of non- ultrasonically bondable materials. For example, if a five-inch wide absorbent core is desired, and a narrower two-inch slit of airiaid absorbent wicking layer is desired to be added in-between selective layers of bonded pocketed SAP.
- a one-and-a-half-inch spacer is added to each side of the airiaid material allowing the two-inch airiaid to be centered and unwound directly as desired, centered between the layers.
- the final bonded together layered rolls may-be spooled, festooned or assembled in such a manner that they are easily unwound into a production converting line.
- the material making up the wicking layer which is only approximately 2 inches wide, would need to be applied across the width of the 16 to 22 inch wide web of the SAP pocketed layers in sequentially spaced strips, with each of those strips being spaced by approximately 3 inches from the next succeeding strip. Accordingly the 16 to 22 wide web can be sequentially cut half way between the sequentially spaced wicking layer strips, to thereby produce a series of 16 to 22 inch long, by 5 inch wide absorbent core assemblies each with a centered 2 inch wide wicking layers for securement to a respective chassis.
- the layers of spunbond like fabrics may be pleated or folded in a corrugated manner to increase the surface area allowing more area for SAP expansion. This can be done for one or more layers. Then this composite core will be run on and through the converting production line as a substitute for the prior pulp/SAP absorbent structure used previously on such production lines.
- the absorbent cores of this invention as described above may be substituted for current pulp/SAP absorbent cores by feeding in at the tissue unwrap/fluff end of the machine in place of the acquisition layer module which may be fed in from the side, or from above, or where ever as appropriate for the various machines marketed today or developed in the future to utilize the composite absorbent core of this invention.
- absorption functionality and softness should be critically managed.
- absorption functionality can be negatively impacted when an overall adhesive bond or overall thermal bond approach is used to bond the layers together.
- These approaches can create a barrier interfering with and slowing the speed of absorption m the absorbent core structure of this invention. Therefore, it is critical to not hinder fluid flow in such a structure.
- edge bonding it needs to be managed to prevent stiffness or hard edges along the sides of the absorbent. These hard edge sides will be perceivable and uncomfortable to a person wearing an absorbent core constructed with a continuous bond. Therefore, in the multiply layer absorbent core structure of this invention, an intermittent bond down each side is desired.
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- Health & Medical Sciences (AREA)
- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Biomedical Technology (AREA)
- Heart & Thoracic Surgery (AREA)
- Vascular Medicine (AREA)
- Epidemiology (AREA)
- Animal Behavior & Ethology (AREA)
- General Health & Medical Sciences (AREA)
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Abstract
Description
Claims
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/625,132 US10588792B2 (en) | 2013-03-15 | 2017-06-16 | Absorbent products and absorbent core for use in same |
US15/709,946 US10335325B2 (en) | 2013-03-15 | 2017-09-20 | Ergonomic disposable absorbent garment |
PCT/US2018/022111 WO2018231301A1 (en) | 2017-06-16 | 2018-03-13 | Absorbent core assemblies, ergonomic disposable absorbent undergarments making use of such core assemblies, and methods of making the same |
Publications (2)
Publication Number | Publication Date |
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EP3638183A1 true EP3638183A1 (en) | 2020-04-22 |
EP3638183A4 EP3638183A4 (en) | 2020-09-16 |
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Application Number | Title | Priority Date | Filing Date |
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EP18817238.1A Withdrawn EP3638183A4 (en) | 2017-06-16 | 2018-03-13 | Absorbent core assemblies, ergonomic disposable absorbent undergarments making use of such core assemblies, and methods of making the same |
Country Status (4)
Country | Link |
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EP (1) | EP3638183A4 (en) |
JP (1) | JP2020524017A (en) |
CA (1) | CA3066486A1 (en) |
WO (1) | WO2018231301A1 (en) |
Family Cites Families (8)
Publication number | Priority date | Publication date | Assignee | Title |
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CA2226485C (en) * | 1995-07-10 | 2002-09-10 | Japan Absorbent Technology Institute | Porous composite sheet and process for the production thereof |
US6478786B1 (en) * | 2000-02-24 | 2002-11-12 | Tyco Healthcare Retail Services Ag | Protective underwear |
CN101621979A (en) * | 2007-03-16 | 2010-01-06 | Sca卫生用品公司 | Elastic absorbent article and a method for its manufacture |
JP4887217B2 (en) * | 2007-05-30 | 2012-02-29 | 株式会社リブドゥコーポレーション | Absorbent articles |
JP5764287B2 (en) * | 2009-08-13 | 2015-08-19 | 株式会社リブドゥコーポレーション | Disposable pants-type diapers |
WO2011162652A1 (en) * | 2010-06-23 | 2011-12-29 | Sca Hygiene Products Ab | A pant-type absorbent article and a method for its manufacture |
US9693911B2 (en) * | 2014-03-11 | 2017-07-04 | Advanced Absorbent Technologies, Llc | Core assembly for absorbing liquids |
JP6364213B2 (en) * | 2014-03-27 | 2018-07-25 | ユニ・チャーム株式会社 | Absorbent articles |
-
2018
- 2018-03-13 CA CA3066486A patent/CA3066486A1/en not_active Abandoned
- 2018-03-13 JP JP2019569252A patent/JP2020524017A/en active Pending
- 2018-03-13 WO PCT/US2018/022111 patent/WO2018231301A1/en active Application Filing
- 2018-03-13 EP EP18817238.1A patent/EP3638183A4/en not_active Withdrawn
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EP3638183A4 (en) | 2020-09-16 |
CA3066486A1 (en) | 2018-12-20 |
WO2018231301A1 (en) | 2018-12-20 |
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