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Fluted composite and related absorbent articles

a technology of absorbent composites and fluted materials, applied in the field of absorbent composites and absorbent articles, can solve the problems of gel blocking of absorbent composites that contain superabsorbent materials, requiring significant energy for their complete drying, and not being used commercially, etc., to achieve the effect of improving liquid wicking, acquisition and distribution

Inactive Publication Date: 2006-04-20
GRAEF PETER A +6
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention provides an absorbent fibrous composite that has absorbent material distributed throughout it and along its length. When the composite is wetted, the absorbent material swells and expands, creating ridges or flutes on the surface of the composite. This fluted structure improves the distribution and wicking of liquid on subsequent insult. Absorbent articles, such as diapers and adult incontinence products, can be made using this fluted composite.

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.

Method used

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  • Fluted composite and related absorbent articles
  • Fluted composite and related absorbent articles
  • Fluted composite and related absorbent articles

Examples

Experimental program
Comparison scheme
Effect test

example 1

Acquisition Times for a Representative Fluted Absorbent Composite

[0170] In this example, the acquisition time for a representative fluted absorbent composite of the present invention (Composite A) is compared to a commercially available diaper (Diaper A, Kimberly-Clark). Also included in the comparison is an absorbent composite (Composite B) having a composition similar to the composite of the invention and composed of fibers (50:50 crosslinked fibers and southern pine pulp fibers), wet strength agent, and absorbent material distributed relatively uniformly throughout the composite. The formation of Composite B is described in provisional U.S. patent application Ser. No. 60 / 046,395, filed May 13, 1997, and international application Serial No. PCT / US98 / 09682, filed May 12, 1998, assigned to Weyerhaeuser Company, each expressly incorporated herein by reference.

[0171] The tests were conducted on commercially available diapers (Kimberly-Clark) from which the core and surge management ...

example 2

Acquisition Rate and Rewet for Representative Fluted Absorbent Composites

[0176] In this example, the acquisition time and rewet of representative fluted absorbent composites of the present invention (designated Composites A1-A4) are compared to a commercially available diaper (Diaper A, Kimberly-Clark). Composites A1-A4 differ by the method by which the composites were dried. Also included in the comparison are a series of absorbent composites (Composites B1-B4) formed as described above for Composite B in Example 1 and differing by the method by which they were dried.

[0177] Certain properties of the tested composites including the amount of superabsorbent polymeric material (weight percent SAP) in the composite and basis weight for each of the composites are summarized in Table 2.

[0178] The tests were conducted on commercially available diapers (Kimberly-Clark) from which the cores were removed and used as surrounds for the fluted absorbent composites and for Composites B1-B4. T...

example 3

Horizontal and Vertical Wicking for a Representative Fluted Absorbent Composite

[0187] In this example, the wicking characteristics of a representative fluted absorbent composite (Composite A) are compared to a commercially available diaper storage core (Diaper B, Procter & Gamble) and a wet-laid storage core having absorbent material distributed uniformly throughout the composite (Composite B).

[0188] The horizontal wicking test measures the time required for liquid to horizontally wick preselected distances. The test is performed by placing a sample composite on a horizontal surface with one end in contact with a liquid bath and measuring the time required for liquid to wick preselected distances. Briefly, a sample composite strip (40 cm×10 cm) is cut from a pulp sheet or other source. If the sheet has a machine direction, the cut is made such that the 40 cm length of the strip is parallel to the machine direction. For absorbent composites of the invention, the strip is centered s...

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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...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D21H17/00A61F13/53A61F5/44A61F13/15A61F13/49B32B5/14B32B23/00D21F9/00D21F11/00D21F11/04D21F11/14D21H23/14
CPCA61F13/15617A61F13/15658A61F13/53A61F13/532A61F13/5323A61F13/535A61F13/53717A61F13/53752A61F13/5376A61F2013/1539A61F2013/4581D21F9/006D21F11/006D21F11/04D21F11/14
Inventor GRAEF, PETER A.BOLSTAD, CLIFFORD R.HOWARD, FRED B.UNRAU, DAVID G.MARSH, DAVID G.MILLER, CHARLES E.HAJNAL, ANDRE S.
Owner GRAEF PETER A
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