Ultra thin laminate with particulates in dense packages

Abstract

The present invention is directed to a method of forming a laminate absorbent structure, and a resulting package containing a single continuous running web of the laminate material. Notably, formation of the material is effected by blending a curtain of adhesive fibers with a curtain of particulate material, and depositing the mixture on a moving substrate, preferably provided in the form of a tissue layer. A second substrate, also preferably comprising a tissue layer, is applied on top of the deposited mixture, and pressure applied to form the laminated structure. Notably, attendant to packaging of the laminated material, adjacent layers of the material tend to nest into one another, to form a sandwich in which the density of the material in the package is more than 1.5 times the density of the material after its removal from the package.

Description

FIELD OF THE INVENTION[0001]The present invention generally relates to thin, laminated materials containing particulates that are supplied as continuous running packages to converting processes and the process and bonding method for making them. Such materials include absorbent core materials that are used to make disposable feminine sanitary absorbent articles and the like that are extremely thin.BACKGROUND OF THE INVENTION[0002]Disposable absorbent articles, such as sanitary napkins, are well known in the art and typically include a fluid pervious body facing cover layer, a liquid impermeable garment facing layer, and an absorbent core structure arranged between the cover layer and garment facing layer. Optionally, such articles may further include a transfer layer arranged between cover layer and the core.[0003]Absorbent core structures used in disposable absorbent articles are typically made mainly of hydrophilic fibrous material such as cellulosic fibers. Such absorbent core st...

AI Technical Summary

Benefits of technology

[0009]In another aspect of the present invention, the present invention contemplates a method of making a laminate absorbent structure, comprising the steps of providing a first moving substrate comprising cellulosic fibrous material. The present method further contemplates providing a supply of adhesive material in the form of a curtain of adhesive fibers, and providing a supply of particulate absorbent material in the form of a curtain of particulate material. In accordance with the present invention, the curtain of particulate material is blended with the curtain of adhesive fibers, above the first moving substrate at a distance of no more than about 2.5 cm above the moving substrate to thus form a mixture of the particulate material and the adhesive fibers. The mixture is then deposited on the moving substrate, with the mixing of the adhesive fibers in the particulate material effected in closely spaced relationship above the moving substrate and order to promote the uniformity of the application of the mixture of adhesive particulate material on the moving substrate.

Problems solved by technology

The inventors of the present invention have discovered that conventional multi-layer core structures having a high superabsorbent polymer content typically have relatively poor structural integrity properties due to the fact that the superabsorbent polymer tends to prevent the effective boding of the constituent core layers.

This problem is further exacerbated when the absorbent core absorbs fluid because the superabsorbent polymer swells upon absorption of fluid thereby further reducing the structural integrity of the core structure.

The relatively poor structural integrity of conventional core structures containing high levels of superabsorbent may cause absorbent articles containing such cores to structurally fail during manufacture or use.

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