Fluted composite and related absorbent articles

Abstract

An absorbent composite that includes a fibrous matrix having absorbent material dispersed in bands along the composite's length is disclosed. The bands define liquid distribution zones. On liquid contact, absorbent material swelling occurs and produces a wetted composite having flutes that include swollen absorbent material separated by distribution zones, regions of the composite that are substantially free of absorbent material. Absorbent articles that include the composite are also disclosed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation of copending international patent application No. PCT / US99 / 05998, filed Mar. 18, 1999, which is a continuation-in-part of U.S. provisional applications No. 60 / 078,779, filed Mar. 19, 1998, No. 60 / 082,771, filed Apr. 23, 1998, No. 60 / 082,790, filed Apr. 23, 1998, and No. 60 / 111,845, filed Dec. 11, 1998, the benefit of the priority of the filing dates of which are hereby claimed under 35 U.S.C. §§120 and 119, respectively. Each of these applications is incorporated herein by reference in its entirety.FIELD OF THE INVENTION [0002] The present invention relates to an absorbent composite and absorbent articles that include the composite. The absorbent composite is a fluted absorbent composite that includes superabsorbent material. BACKGROUND OF THE INVENTION [0003] Cellulose fibers derived from wood pulp are used in a variety of absorbent articles, for example, diapers, incontinence products, and feminine h...

AI Technical Summary

Benefits of technology

[0008] In one aspect, the present invention provides an absorbent fibrous composite containing absorbent material dispersed through the composite and along the composite's length. On wetting, liquid acquired by the composite is distributed throughout the composite and ultimately absorbed by the composite's absorbent material. In one embodiment, the absorbent material is dispersed along the composite's length in bands. For such an embodiment, the absorbent material swells with acquired liquid and the portion of the composite that includes absorbent material expands and raises from the composite's wetted surface to form ridges or flutes. The wetted composite's fluted structure enhances liquid wicking, acquisition, and distribution on subsequent liquid insult.

Problems solved by technology

Wet-laid processes for forming cellulose mats have not been used commercially because superabsorbent polymers tend to absorb liquid and swell during formation of the absorbent mats, thus requiring significant energy for their complete drying.

However, absorbent composites that contain superabsorbent materials commonly suffer from gel blocking.

By preventing distribution of acquired liquid from a composite's unwetted portions, gel blocking precludes the effective and efficient use of superabsorbent materials in fibrous composites.

The wicking capacity of conventional fibrous composites that include relatively homogeneous distributions of superabsorbent material is generally significantly restricted after initial liquid insult.

The diminished capacity of such fibrous composites results from narrowing of capillary acquisition and distribution channels that accompanies superabsorbent material swelling.

The diminution of absorbent capacity and concomitant loss of capillary distribution channels for conventional absorbent cores that include superabsorbent material is manifested by decreased liquid acquisition rates and far from ideal liquid distribution on successive liquid insults.

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