Absorbent structures and methods of making absorbent structures

Abstract

Absorbent structures and methods of manufacture are disclosed. In one embodiment, a method of manufacture can include directing a stream of particles toward a layer, spraying a first binder toward the stream, the first binder contacting the stream at a first point of contact, spraying a second binder toward the stream, the second binder contacting the stream at a second point of contact, the first point of contact being different than the second point of contact, depositing the mixed particles, first binder, and second binder onto the layer, and covering the mixture of particles, first binder, and second binder with a second layer.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to absorbent structures, and more particularly to absorbent structures having high superabsorbent material content. BACKGROUND

[0002] The primary function of personal care absorbent articles is to absorb and retain bodily exudates such as urine, fecal matter, blood, and menses, and also has additional desirable attributes including little exudate leakage from the absorbent article and a dry feel for the wearer of the absorbent article. Absorbent articles aim to prevent bodily exudates from soiling or staining the clothing of the wearer or caregiver, or other articles such as bedding that can come into contact with the wearer, by preventing exudate leakage from the absorbent article.

[0003] Absorbent cores generally contribute to liquid intake and storage within an absorbent article. Many absorbent cores contain a variety of absorbent materials such as superabsorbent materials and pulp fluff or other fibrous absorbent materials. Each type of absorbent material contributes to imparting a range of properties to such absorbent cores that can be used to absorb and retain liquid bodily exudates. For example, pulp fluff or other fibrous absorbent materials can absorb liquid faster than superabsorbent materials, and superabsorbent materials can retain more liquid per particle than pulp fluff.

[0004] Absorbent cores, particularly the superabsorbent materials of absorbent cores, have seen many advances. Some current absorbent cores can now have absorbent materials that primarily comprise superabsorbent materials and further comprise only a small portion of other absorbent materials. Other current absorbent cores contain only superabsorbent materials as absorbent materials. There is a constant need for further developments of absorbent cores having high superabsorbent material content to further improve the performance of such absorbent cores. SUMMARY

[0005] Absorbent structures and methods of making such absorbent structures are disclosed in the present disclosure. In a first embodiment, a method of making an absorbent structure can comprise directing a stream of first superabsorbent particles toward a first layer of substrate material moving in a machine direction, the stream of first superabsorbent particles having a first side and a second side, spraying a first adhesive toward the first side of the stream of first superabsorbent particles with a first adhesive applicator having a first adhesive nozzle, the first adhesive contacting the stream of first superabsorbent particles and mixing with the superabsorbent particles of the stream of first superabsorbent particles before the superabsorbent particles are deposited onto the first layer of substrate material, the first adhesive contacting the stream of first superabsorbent particles at a first point of contact having a first height measured from the first layer of substrate material, spraying a second adhesive toward the second side of the stream of first superabsorbent particles with a second adhesive applicator having a second adhesive nozzle, the second adhesive contacting the stream of first superabsorbent particles and mixing with the superabsorbent particles of the stream of first superabsorbent particles before the superabsorbent particles are deposited onto the first layer of substrate material, the second adhesive contacting the stream of first superabsorbent particles at a second point of contact having a second height measured from the first layer of substrate material, the first height being different than the second height, depositing the mixed superabsorbent particles, first adhesive, and second adhesive of the stream of first superabsorbent particles onto the first layer of substrate material, and covering the mixture of the superabsorbent particles, the first adhesive, and the second adhesive of the stream of first superabsorbent particles with a second layer of substrate material.

[0006] In a second embodiment, a method of making an absorbent structure can comprise: directing a first stream of superabsorbent particles toward a first layer of substrate material, the first stream of superabsorbent particles having a first side and a second side; spraying a first adhesive with a first adhesive applicator having a first adhesive nozzle toward the first side of the first stream of superabsorbent particles, the first adhesive contacting the first stream of superabsorbent particles and mixing with the superabsorbent particles of the first stream of superabsorbent particles before the superabsorbent particles are deposited onto the first layer of substrate material; depositing the mixed superabsorbent particles of the first stream of superabsorbent particles and the first adhesive onto the first layer of substrate material; directing a second stream of superabsorbent particles toward the deposited mixture of the superabsorbent particles of the first stream of superabsorbent particles and the first adhesive, the second stream of superabsorbent particles having a first side and a second side; spraying a second adhesive with a second adhesive applicator having a second adhesive nozzle toward one of the first side and the second side of the second stream of superabsorbent particles, the second adhesive contacting the second stream of superabsorbent particles and mixing with the superabsorbent particles of the second stream of superabsorbent particles before the superabsorbent particles are deposited onto the deposited mixture of the superabsorbent particles of the first stream of superabsorbent particles and the first adhesive; depositing the mixed superabsorbent particles of the second stream of superabsorbent particles and the second adhesive onto the deposited mixture of the superabsorbent particles of the first stream of superabsorbent particles and the first adhesive; and covering the deposited mixture of the superabsorbent particles of the first stream of superabsorbent particles and the first adhesive and the superabsorbent particles of the second stream of superabsorbent particles and the second adhesive with a second layer of substrate material.

[0007] In a third embodiment, the method of manufacturing the absorbent structure may include: guiding a first superabsorbent particle stream to a first substrate material layer, the first superabsorbent particle stream having a first side and a second side, wherein the first superabsorbent particle stream is supplied such that the superabsorbent particles of the first superabsorbent particle stream form a first superabsorbent particle layer with a matrix weight of superabsorbent particles greater than 200 gsm; spraying a first adhesive onto the first side of the first superabsorbent particle stream using a first adhesive applicator having a first adhesive nozzle, the first adhesive contacting the first superabsorbent particle stream and mixing with the superabsorbent particles of the first superabsorbent particle stream before the superabsorbent particles are deposited onto the first substrate material layer; and using a second first adhesive with a second adhesive nozzle. An applicator sprays a second adhesive onto the second side of the first superabsorbent particle stream. The second adhesive contacts the first superabsorbent particle stream and mixes with the superabsorbent particles of the first superabsorbent particle stream before the superabsorbent particles are deposited onto the first substrate material layer. The mixed superabsorbent particles, the first adhesive, and the second adhesive of the first superabsorbent particle stream are deposited onto the first substrate material layer. The total amount of adhesive mixed with the superabsorbent particles of the first superabsorbent particle layer is less than 5% by weight of the superabsorbent particles in the first superabsorbent particle layer. The mixture of the superabsorbent particles, the first adhesive, and the second adhesive of the first superabsorbent particle stream is covered with a second substrate material layer. Attached Figure Description

[0008] The complete and practicable disclosure of the invention, presented to those skilled in the art, is set forth in more detail in the remainder of the specification with reference to the accompanying drawings, in which:

[0009] Figure 1 This is a side perspective view of an exemplary embodiment of an absorbent article (such as a diaper) in a secured state.

[0010] Figure 2 It is in a stretched and relaxed state. Figure 1 Top plan view of the absorbent material.

[0011] Figure 3 This is a front perspective view of an alternative implementation of absorbent products (such as trousers).

[0012] Figure 4 It is in a stretched and flat state. Figure 3 Top plan view of the absorbent material.

[0013] Figure 5 It is along Figure 2 The front perspective cross-section of line 5-5 shows the absorbent article in a relaxed configuration.

[0014] Figure 6 is a process schematic depicting an example method of making an absorbent structure according to the present disclosure.

[0015] Figure 7 is a process schematic depicting a portion of an example method of making an absorbent structure according to the present disclosure. Figure 6

[0016] Figure 8 is a process schematic depicting an alternative example method of making an absorbent structure according to the present disclosure.

[0017] Figures 9A-9C is a different example front cross-sectional view of an absorbent structure formed according to aspects of the present disclosure taken along line 9-9 of Figure 8

[0018] Figures 10A-10B is a different example front cross-sectional view of an absorbent structure formed according to aspects of the present disclosure taken along line 10-10 of Figure 8

[0019] Figure 11A is a top perspective view of a three-dimensional image generated from an example mixture of particles and adhesive filaments formed by the process of Figure 8

[0020] Figure 11B is a top plan view of the three-dimensional image of Figure 11A

[0021] Figure 11C is a cross-sectional view of a slice of the three-dimensional image of Figure 11A

[0022] Figure 11D is a cross-sectional view of Figure 11C

[0023] It is intended that the use of identical or similar reference numerals in the disclosure DETAILED DESCRIPTION

[0024] In one embodiment, the present disclosure is generally directed to an absorbent core comprising a high proportion of superabsorbent material. Each example is given by way of illustration and is not meant to limit. For example, features illustrated or described as part of one embodiment, can be used with another embodiment to yield still a further embodiment. It is intended that the present disclosure include such modifications and variations.

[0025] ​​​​​​​When introducing elements of the disclosure or the preferred embodiments thereof, the articles "a," "an," "the" and "said" are intended to mean that there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there can be additional elements other than the listed elements. Numerous modifications and adaptations will be apparent to those skilled in the art without departing from the spirit and scope of the disclosure. Therefore, the above-described exemplary embodiments should not be construed as limiting the scope of the present disclosure, but rather as merely providing examples, which, while they can be the most preferred embodiments, do not encompass all aspects of the present disclosure.

[0026] Definitions:

[0027] The term "absorbent article" refers herein to an article that can be placed against or in proximity to (i.e., adjacent to) a wearer's body to absorb and contain various liquid, solid, and semi-solid exudates discharged from the body. Such absorbent articles as described herein are intended to be discarded after a limited period of use and are not intended to be laundered or otherwise restored for reuse. It should be understood that the present disclosure applies to a variety of disposable absorbent articles, including but not limited to diapers, training pants, pull-on diapers, larger child pants, swim pants, feminine hygiene products including but not limited to sanitary napkins or sanitary pants, incontinence products and other adult care garments, medical garments, surgical pads and bandages, other personal care or health care garments, and the like, without departing from the scope of the disclosure.

[0028] The term "acquisition layer" refers herein to a layer that is capable of receiving and temporarily holding liquid body exudates to slow and spread the gush or surge of liquid body exudates and subsequently release the liquid body exudates therefrom into another layer or layers of the absorbent article.

[0029] The terms "bonded" or "coupled" refer herein to the joining, adhering, connecting, attaching, or the like, of two elements. Two elements will be considered bonded or coupled together when they are joined, adhered, connected, attached, or the like, directly to one another or to the same element. Bonding or coupling of one element to another element can occur via continuous or intermittent bonding.

[0030] The term "carded web" refers herein to a web containing natural or synthetic staple length fibers having a fiber length generally less than 100 mm. The staple fiber bundle can be subjected to an opening process to separate the fibers, after which the fibers are fed to a carding process that separates and aligns the fibers in the machine direction, after which the fibers are deposited on a moving wire for further processing. Such webs are typically subjected to some sort of bonding process, such as thermal bonding using heat and / or pressure. Additionally or alternatively, the fibers can be subjected to an adhesive process to bond the fibers together, for example, using a powder adhesive. Carded webs can be subjected to hydroentanglement, for example, to further entangle the fibers and thereby increase the integrity of the carded web. Because the fibers are aligned in the machine direction, carded webs typically have greater machine direction strength than cross machine direction strength once bonded.

[0031] "Elastomeric" refers to a material or composite that can be elongated by at least 50% of its relaxed length and will recover at least 20% of its elongation after release of an applied force. It is generally preferred that the elastomeric material or composite be capable of being elongated by at least 50% of its relaxed length, more preferably by at least 100%, and still more preferably by at least 300%, and recover at least 50% of its elongation after release of an applied force.

[0032] The term "film" refers herein to a thermoplastic film made by an extrusion and / or forming process, such as a cast film or blown film extrusion process. This term includes apertured films, slit films, and other porous films that constitute liquid transfer films, as well as films that do not transfer fluids, such as, but not limited to, barrier films, filled films, breathable films, and oriented films.

[0033] The term "gsm" refers herein to grams per square meter.

[0034] The term "hydrophilic" refers herein to a fiber or fiber surface that is wetted by an aqueous liquid with which it comes in contact. The degree of wetting of a material can also be described in terms of the contact angle and surface tension of the liquid and material involved. Suitable equipment and techniques for measuring the wettability of a particular fiber material or blend of fiber materials can be provided by a Cahn SFA-222 Surface Force Analyzer System or a substantially equivalent system. When measured using this system, fibers having a contact angle of less than 90 degrees are identified as "wettable" or hydrophilic, and fibers having a contact angle of greater than 90 degrees are identified as "non-wettable" or hydrophobic.

[0035] The term "liquid impermeable" refers herein to a layer or layers of laminate material wherein a liquid bodily exudate, such as urine, will not pass through the layer or laminate material in a direction generally perpendicular to the plane of said layer or laminate at the point of liquid contact under ordinary use conditions.

[0036] The term "liquid permeable" refers herein to any material that is not liquid impermeable.

[0037] The term "meltblown" refers herein to fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries of a meltblown process into converging high velocity heated gas (e.g., air) streams. Such streams have a tendency to attenuate the molten thermoplastic material in a manner to reduce its diameter, which can be microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Patent No. 3,849,241 to Butin et al., which is incorporated herein by reference. Meltblown fibers are microfibers which can be continuous or discontinuous, are generally smaller than 0.6 denier, and can be tacky and self-bonding when deposited on a collecting surface.

[0038] The term "nonwoven" refers herein to a material or web of material formed without the aid of a textile weaving or knitting process. The material or web can have a structure of individual fibers, filaments, or threads (collectively referred to as "fibers") which can be interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven materials or webs can be formed from many processes such as, but not limited to, meltblowing processes, spunbonding processes, carding processes, etc.

[0039] The term "flexible" refers herein to a material that is compliant and readily conforms to the general shape and contours of the wearer's body.

[0040] The term "spunbond" refers herein to small diameter fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine capillaries of a spinneret, and then rapidly reducing the diameter of the extruded filaments by drawing and other conventional processes described in, for example, U.S. Patent Nos. 4,340,563 to Appel et al., 3,692,618 to Dorschner et al., 3,802,817 to Matsuki et al., 3,338,992 and 3,341,394 to Kinney, 3,502,763 to Hartmann, 3,502,538 to Peterson, and 3,542,615 to Dobo et al., each of which is incorporated herein by reference in its entirety. Spunbond fibers are substantially continuous and usually have an average denier of greater than 0.3, and in one embodiment between 0.6, 5 and 10 and 15, 20 and 40. Spunbond fibers are usually not tacky when deposited onto a collecting surface.

[0041] The term "superabsorbent" refers herein to a water-swellable, water-insoluble organic or inorganic material capable of absorbing at least 15 times its weight, and in one embodiment at least 30 times its weight, in an aqueous solution containing 0.9 weight percent sodium chloride at most favorable conditions. Superabsorbent materials can be natural, synthetic and modified natural polymers and materials. In addition, the superabsorbent materials can be inorganic materials, such as silica gels, or organic compounds, such as crosslinked polymers.

[0042] The term "supermajority" refers herein to a majority of at least 65%.

[0043] The term "thermoplastic" refers herein to a material which softens and which can be shaped when exposed to heat and which substantially returns to a non-softened condition when cooled.

[0044] The term "user" or "caregiver" refers herein to a person who fits an absorbent article, such as but not limited to a diaper, a pull-on, a training pant, a larger child's pant, an incontinence product, or other absorbent article, around a wearer of one of these absorbent articles. The user and the wearer can be the same person.

[0045] Absorbent article:

[0046] See Figures 1-2A non-limiting illustration of an absorbent article 10 (e.g., a diaper) is shown. While the embodiments and illustrations described herein can be generally applied to absorbent articles manufactured in the longitudinal direction of a product (hereinafter referred to as machine-direction manufacturing of the product), it should be noted that those skilled in the art can apply the information herein to absorbent articles manufactured in the latitudinal direction of a product, hereinafter referred to as transverse machine-direction manufacturing of the product, without departing from the spirit and scope of this disclosure. For example, Figures 3-4 The absorbent article 210 provided in the example embodiment is an absorbent article 210 that can be manufactured in a manufacturing process across the machine direction.

[0047] Figure 1 and Figure 2 The absorbent article 10 shown in the figure and Figure 3 and Figure 4 The absorbent articles 210 shown may each include a backsheet 11. The absorbent articles 10 and 210 may include a front waist region 12, a rear waist region 14, and a crotch region 16, wherein the crotch region is disposed between the front waist region 12 and the rear waist region 14 and interconnects the front waist region 12 and the rear waist region 14, respectively. The front waist region 12 may be referred to as the front end region, the rear waist region 14 may be referred to as the rear end region, and the crotch region 16 may be referred to as the middle region. Figure 3 and Figure 4 The illustrated embodiment depicts a three-piece construction of absorbent article 210, wherein absorbent article 210 may have a backsheet 11 comprising a front waist piece 13 defining a front waist region 12, a back waist piece 15 defining a back waist region 14, and an absorbent sheet 17 defining a crotch region 16 of absorbent article 210. Absorbent sheet 17 may extend between the front waist piece 13 and the back waist piece 15. In some embodiments, absorbent sheet 17 may overlap with the front waist piece 13 and the back waist piece 15. Absorbent sheet 17 may be bonded to the front waist piece 13 and the back waist piece 15 to define the three-piece construction. However, it is contemplated that the absorbent article may be manufactured across the machine direction without being a three-piece garment.

[0048] Absorbent articles 10, 210 may have a pair of longitudinal side edges 18, 20 and a pair of opposing waist edges, designated as a front waist edge 22 and a rear waist edge 24, respectively. A front waist region 12 may be adjacent to the front waist edge 22, and a rear waist region 14 may be adjacent to the rear waist edge 24. The longitudinal side edges 18, 20 may extend from the front waist edge 22 to the rear waist edge 24. The longitudinal side edges 18, 20 may extend along their entire length in a direction parallel to the longitudinal direction 30, such as for... Figure 1 and Figure 2 Regarding the absorbent article 10 shown. In other embodiments, the longitudinal side edges 18, 20 may be curved between the front waist edge 22 and the rear waist edge 24. Figure 3 and 4In the absorbent article 210, the longitudinal side edges 18, 20 can include portions of the front waist panel 13, the absorbent panel 17, and the back waist panel 15.

[0049] The front waist region 12 can include a portion of the absorbent article 10, 210 that, when worn, is positioned at least partially on the front of the wearer, while the back waist region 14 can include a portion of the absorbent article 10, 210 that, when worn, is positioned at least partially on the back of the wearer. The crotch region 16 of the absorbent article 10, 210 can include a portion of the absorbent article 10, 210 that, when worn, is positioned between the legs of the wearer and can partially cover the lower torso of the wearer. The waist edges 22 and 24 of the absorbent article 10, 210 are configured to encircle the waist of the wearer and together define a central waist opening 23 (as marked in Figure 1 and Figure 3 When the absorbent article 10, 210 is worn, the portions of the longitudinal side edges 18, 20 in the crotch region 16 can generally define leg openings for the legs of the wearer.

[0050] The absorbent article 10, 210 can include an outer cover 26 and a body side liner 28. The outer cover 26 and the body side liner 28 can form a portion of the backsheet 11. In one embodiment, the body side liner 28 can be adhesively bonded to the outer cover 26 in a superposed relationship by any suitable means such as, but not limited to, adhesives, ultrasonic bonding, thermal bonding, pressure bonding, or other conventional techniques. The outer cover 26 can define a length in the longitudinal direction 30 and a width in the transverse direction 32, which in the illustrated embodiment can coincide with the length and width of the absorbent article 10. As shown in Figure 2 and Figure 4 The absorbent article 10, 210 can have a longitudinal axis 29 extending in the longitudinal direction 30 and a transverse axis 31 extending in the transverse direction 32.

[0051] The backsheet 11 can include an absorbent body 34. The absorbent body 34 can be disposed between the outer cover 26 and the body-side liner 28. The absorbent body 34 can have longitudinal edges 36 and 38, which in one embodiment, can form portions of the longitudinal side edges 18 and 20, respectively, of the absorbent article 10, 210. The absorbent body 34 can have a first end edge 40 opposite a second end edge 42, which in one embodiment, can form portions of the waist edges 22 and 24, respectively, of the absorbent article 10. In some embodiments, the first end edge 40 can be in the front waist region 12. In some embodiments, the second end edge 42 can be in the back waist region 14. In one embodiment, the absorbent body 34 can have a length and a width that is the same as or less than the length and width of the absorbent article 10, 210. The body-side liner 28, the outer cover 26, and the absorbent body 34 can form a portion of an absorbent assembly 44. In Figure 3 and 4 The absorbent body 34 can form the absorbent assembly 44 in the absorbent article 210 of Figure 5 As is known in the art, the absorbent assembly 44 can also include a fluid transfer layer 46 (as shown in Figure 5 ) and a fluid acquisition layer (not shown) between the body-side liner 28 and the fluid transfer layer 46. The absorbent assembly 44 can also include a spacer layer 48 (as shown in

[0052] The absorbent article 10, 210 can be configured to contain and / or absorb liquid, solid, and semi-solid body exudates discharged from a wearer. In some embodiments, the containment flaps 50, 52 can be configured to provide a barrier against lateral flow of body exudates. To further enhance the containment and / or absorbent effect of body exudates, the absorbent article 10, 210 can suitably include a waist containment member 54. In some embodiments, the waist containment member 54 can be disposed in the back waist region 14 of the absorbent article 10, 210. Although not shown herein, it is contemplated that the waist containment member 54 can be disposed in the front waist region 12 of the absorbent article 10, 210 in addition to or instead of.

[0053] The waist containment member 54 can be disposed on the body-facing surface 19 of the backsheet 11 to help contain and / or absorb body exudates. In some embodiments, such as in the absorbent article 10 depicted in Figure 1 and Figure 2 The waist containment member 54 can be disposed on the body-facing surface 45 of the absorbent assembly 44. In some embodiments, the waist containment member 54 can be disposed on the body-facing surface 56 of the body-side liner 28. In some embodiments, such as in the absorbent article 10 depicted in Figure 3 and Figure 4In the depicted absorbent article 210, the waist containment member 54 can be disposed on the body-facing surface 58 of the back waist panel 15.

[0054] The absorbent articles 10, 210 can further include leg elastics 60, 62 known to those skilled in the art. The leg elastics 60, 62 can be attached to the outer cover 26 and / or the body side liner 28 along opposite longitudinal side edges 18 and 20 and positioned in the crotch region 16 of the absorbent article 10, 210. The leg elastics 60, 62 can be parallel to the longitudinal axis 29, as shown in Figure 2 and 4 shown in Figs. 1-2; or can be curved as known in the art. The leg elastics 60, 62 can be elastomeric and can provide an elasticized leg cuff.

[0055] In some embodiments, the absorbent articles 10, 210 can further include longitudinally extending fold lines 25a, 25b, as shown in Figure 2 and Figure 4 Fig. 3. The first longitudinally extending fold line 25a can be on one side of the longitudinal axis 29 of the absorbent article 10, 210, while the second longitudinally extending fold line 25b can be on the opposite side of the longitudinal axis 29. In some embodiments, the longitudinally extending fold lines 25a, 25b can be generally parallel to the longitudinal axis 29 of the absorbent article 10, 210. In some embodiments, the absorbent articles 10, 210 can further include a transversely extending fold line 27. In some embodiments, the transversely extending fold line 27 can be parallel to and at the lateral axis 31 of the absorbent article 10, 210.

[0056] Further details regarding each of these elements of the absorbent articles 10, 210 described herein can be seen hereinafter and with reference to the accompanying drawings.

[0057] Outer Cover:

[0058] The outer cover 26 and / or portions thereof can be breathable and / or liquid impermeable. The outer cover 26 and / or portions thereof can be elastic, stretchable, or non-stretchable. The outer cover 26 can be constructed from a single layer, multiple layers, a laminate, a spunbond fabric, a film, a meltblown fabric, an elastic netting, a microporous web, a bonded-carded web, or a foam provided by an elastomer or a polymeric material. In one embodiment, for example, the outer cover 26 can be constructed from a microporous polymeric film such as polyethylene or polypropylene.

[0059] In one embodiment, the outer coating 26 may be a single-layer liquid-impermeable material, such as a polymer film. In one embodiment, the outer coating 26 may be suitably stretchable, and more suitably elastic, at least in the transverse direction 32 of the absorbent articles 10, 210. In one embodiment, the outer coating 26 may be stretchable, and more suitably elastic, in both the transverse direction 32 and the longitudinal direction 30. In one embodiment, the outer coating 26 may be a multilayer laminate, wherein at least one layer is liquid-impermeable. In some embodiments, the outer coating 26 may be a two-layer construction comprising an outer layer (not shown) and an inner layer (not shown) that can be bonded together, for example, by a laminate adhesive. Suitable laminate adhesives may be applied continuously or intermittently as beads, spray, parallel vortex, etc., but it should be understood that the inner layer may be bonded to the outer layer by other bonding methods including, but not limited to, ultrasonic bonding, thermal bonding, pressure bonding, etc.

[0060] The outer layer 26 can be any suitable material and can be a material that provides the wearer with a generally fabric-like texture or appearance. An example of such a material could be a 100% polypropylene bonded combed web with a diamond-patterned bonding structure, available from Sandler AG in Germany, for example, 30gsm Sawabond. Or equivalent. Another example of a material suitable for use as the outer layer of the outer cover 26 could be a 20 gsm spunbond polypropylene nonwoven web. The outer layer may also be constructed of the same material as that which can be used to construct the body side lining 28 as described herein.

[0061] The liquid-impermeable inner layer of the outer cover 26 (or the liquid-impermeable outer cover 26, in which case the outer cover 26 has a single-layer construction) can be vapor-permeable (i.e., "breathable") or vapor-impermeable. The liquid-impermeable inner layer (or the liquid-impermeable outer cover 26 when the outer cover 26 has a single-layer construction) can be made of a thin plastic film. The liquid-impermeable inner layer (or the liquid-impermeable outer cover 26, in which case the outer cover 26 has a single-layer construction) can prevent liquid bodily exudates from leaking from the absorbent articles 10, 210 and wetting articles such as sheets and clothing, as well as the wearer and caregiver.

[0062] In some embodiments, where the outer coating 26 has a single-layer construction, it may be embossed and / or textured to provide a more fabric-like texture or appearance. The outer coating 26 allows vapor to escape from the absorbent article 10 while preventing liquid penetration. Suitable liquid-impermeable, vapor-permeable materials may be composed of microporous polymer membranes or nonwoven materials that have been coated or otherwise treated to impart a desired level of liquid impermeability.

[0063] Body side lining:

[0064] The body side liner 28 of the absorbent articles 10, 110, 210 can overlie the absorbent body 34 and the outer cover 26 and can isolate the wearer's skin from waste retained by the absorbent body 34. In various embodiments, a fluid transfer layer 46 can be positioned between the body side liner 28 and the absorbent body 34. In various embodiments, a acquisition layer (not shown) can be positioned between the body side liner 28 and the absorbent body 34 or the fluid transfer layer 46, if present. In various embodiments, the body side liner 28 can be bonded to the acquisition layer or the fluid transfer layer 46, if the acquisition layer is not present, via adhesive and / or by point fusion bonding. Point fusion bonding can be selected from ultrasonic bonding, thermal bonding, pressure bonding, and combinations thereof.

[0065] In one embodiment, the body side liner 28 can extend beyond the absorbent body 34 and / or the fluid transfer layer 46, if present, and / or the acquisition layer, if present, and / or the spacer layer 48, if present, so as to overlie a portion of the outer cover 26 and can be bonded to the outer cover by any method deemed suitable, such as by adhesive bonding to the outer cover, to substantially enclose the absorbent body 34 between the outer cover 26 and the body side liner 28. The body side liner 28 can be narrower than the outer cover 26. However, in other embodiments, the body side liner 28 and the outer cover 26 can have the same width and length dimensions. In other embodiments, the body side liner 28 can be wider than the outer cover 26. It is also contemplated that the body side liner 28 can not extend beyond the absorbent body 34 and / or can not be secured to the outer cover 26. In some embodiments, the body side liner 28 can wrap at least a portion of the absorbent body 34, including wrapping around the longitudinal edges 36, 38 and / or the one or more end edges 40, 42 of the absorbent body 34. It is further contemplated that the body side liner 28 can be constructed of more than one material segment. The body side liner 28 can have different shapes, including rectangular, hourglass, or any other shape. The body side liner 28 can be suitably conformable, soft and comfortable, and non-irritating to the wearer's skin, and can be the same or lower hydrophilicity as the absorbent body 34 to allow body exudates to readily penetrate to the absorbent body 34 and provide a relatively dry surface for the wearer.

[0066] The body side liner 28 can be made of various types of materials, such as synthetic fibers (e.g., polyester fibers or polypropylene fibers), natural fibers (e.g., wood fibers or cotton fibers), combinations of natural fibers and synthetic fibers, porous foams, honeycomb foams, apertured plastic films, and the like. Examples of suitable materials include, but are not limited to, rayon, wood, cotton, polyester, polypropylene, polyethylene, nylon, or other heat-bondable fibers, polyolefins such as, but not limited to, copolymers of polypropylene and polyethylene, linear low-density polyethylene, and aliphatic esters such as polylactic acid, fine-mesh film webs, net materials, and the like, and combinations thereof.

[0067] Various woven and nonwoven fabrics can be used for the body side liner 28. The body side liner 28 can include woven fabrics, nonwoven fabrics, polymeric films, film-fabric laminates, and the like, and combinations thereof. Examples of nonwoven fabrics can include spunbond fabrics, meltblown fabrics, coform fabrics, carded webs, bonded carded webs, bicomponent spunbond fabrics, spunlace, and the like, and combinations thereof. The body side liner 28 need not be a single layer structure, and thus can include more than one layer of fabric, film, and / or web, and combinations thereof. For example, the body side liner 28 can include a support layer and a projection layer that can be hydroentangled. The projection layer can include hollow projections such as those disclosed in U.S. Patent No. 9,474,660 to Kirby, Scott S.C., et al.

[0068] For example, the body side liner 28 can be constructed of a meltblown or spunbond web of polyolefin fibers. Alternatively, the body side liner 28 can be a bonded carded web constructed of natural fibers and / or synthetic fibers. The body side liner 28 can be constructed of a substantially hydrophobic material, and the hydrophobic material can optionally be treated or otherwise processed with a surfactant to impart a desired level of wettability and hydrophilicity. The surfactant can be applied by any conventional means such as spraying, printing, brushing, and the like. The surfactant can be applied to the entire body side liner 28, or can be selectively applied to particular sections of the body side liner 28.

[0069] In one embodiment, the body side liner 28 can be constructed of a nonwoven bicomponent web. The nonwoven bicomponent web can be a spunbond bicomponent web or a bonded carded bicomponent web. Examples of bicomponent staple fibers include polyethylene / polypropylene bicomponent fibers. In this particular bicomponent fiber, the polypropylene forms the core and the polyethylene forms the sheath of the fiber. Fibers having other orientations such as, for example, multi-lobed, side-by-side, end-to-end can be used without departing from the scope of the disclosure. In one embodiment, the body side liner 28 can be a spunbond substrate having a basis weight of 10 or 12 to 15 or 20 gsm. In one embodiment, the body side liner 28 can be a 12 gsm spunbond-spunmelt-spunbond substrate with 10% spunmelt content applied between the two spunbond layers.

[0070] While the outer cover 26 and the body side liner 28 can comprise elastomeric materials, it is contemplated that the outer cover 26 and the body side liner 28 can be constructed of substantially non-elastomeric materials. In one embodiment, the body side liner 28 can be stretchable, and more suitably elastic. In one embodiment, the body side liner 28 can be suitably stretchable, and more suitably elastic, at least in the transverse or circumferential direction of the absorbent article 10, 210. In other aspects, the body side liner 28 can be stretchable, and more suitably elastic, in both the transverse direction 32 and the longitudinal direction 30, respectively.

[0071] Containment flaps:

[0072] In one embodiment, the absorbent article 10, 210 can include a pair of containment flaps 50, 52. The containment flaps 50, 52 can be formed separately from the absorbent chassis 11 and attached to the chassis 11, or can be formed integral with the chassis 11. In one embodiment, the containment flaps 50, 52 can be secured to the chassis 11 of the absorbent article 10, 210 in a generally parallel spaced relationship to one another from the leg openings in the transverse direction to provide a barrier to the flow of body exudates. One containment flap 50 can be on a first side of the longitudinal axis 29, while the other containment flap 52 can be on a second side of the longitudinal axis 29. In one embodiment, the containment flaps 50, 52 can extend from the front waist region 12 of the absorbent article 10 generally in the longitudinal direction 30 through the crotch region 16 to the back waist region 14 of the absorbent article 10. In some embodiments, the containment flaps 50, 52 can extend in a direction substantially parallel to the longitudinal axis 29 of the absorbent article 10, 210, but in other embodiments, the containment flaps 50, 52 can be curved as is known in the art. In other embodiments, such as in the absorbent article 210 in Figure 3 and Figure 4 the absorbent article 210 in

[0073] In embodiments where the containment flaps 50, 52 are coupled to the chassis 11, the containment flaps 50, 52 can be bonded to the body side liner 28 with a barrier adhesive 49 as shown in Figure 5 Alternatively, the containment flaps 50, 52 can be bonded to the outer cover 26 with the barrier adhesive 49, or to the spacer layer 48. Of course, the containment flaps 50, 52 can be bonded to other components of the chassis 11, and can be bonded with other suitable means than the barrier adhesive 49. The containment flaps 50, 52 can be constructed of a fibrous material, which can be similar to the material forming the body side liner 28. Other conventional materials, such as polymeric films, can also be employed.

[0074] The containment flaps 50, 52 can each include a base portion 64 and a protruding portion 66. The base portion 64 can be bonded to the chassis 11, for example, to the body-side liner 28 or the outer cover 26 as described above. The base portion 64 can include a proximal end 64a and a distal end 64b. The protruding portion 66 can be separated from the base portion 64 at the proximal end 64a of the base portion 64. As used in this context, the protruding portion 66 is separated from the base portion 64 at the proximal end 64a of the base portion 64 because the proximal end 64a of the base portion 64 defines the transition between the protruding portion 66 and the base portion 64. The proximal end 64a of the base portion 64 can be located proximate the barrier adhesive 49. In some embodiments, the distal end 64b of the base portion 64 can extend laterally to the respective longitudinal side edge 18, 20 of the absorbent article 10, 210. In other embodiments, the distal end 64b of the base portion 64 can end laterally inward of the respective longitudinal side edge 18, 20 of the absorbent article 10, 210. The containment flaps 50, 52 can also each include a protruding portion 66 that is configured to extend away from the body-facing surface 19 of the chassis 11 at least in the crotch region 16 when the absorbent article 10, 210 is in a relaxed configuration, as shown in FIG. 1. The containment flaps 50, 52 can comprise a tacked region 71 in either or both of the front waist region 12 and the back waist region 14 where the protruding portion 66 is coupled to the body-facing surface 19 of the chassis 11. Figure 5 The containment flaps 50, 52 can each include a base portion 64 and a protruding portion 66. The base portion 64 can be bonded to the chassis 11, for example, to the body-side liner 28 or the outer cover 26 as described above. The base portion 64 can include a proximal end 64a and a distal end 64b. The protruding portion 66 can be separated from the base portion 64 at the proximal end 64a of the base portion 64. As used in this context, the protruding portion 66 is separated from the base portion 64 at the proximal end 64a of the base portion 64 because the proximal end 64a of the base portion 64 defines the transition between the protruding portion 66 and the base portion 64. The proximal end 64a of the base portion 64 can be located proximate the barrier adhesive 49. In some embodiments, the distal end 64b of the base portion 64 can extend laterally to the respective longitudinal side edge 18, 20 of the absorbent article 10, 210. In other embodiments, the distal end 64b of the base portion 64 can end laterally inward of the respective longitudinal side edge 18, 20 of the absorbent article 10, 210. The containment flaps 50, 52 can also each include a protruding portion 66 that is configured to extend away from the body-facing surface 19 of the chassis 11 at least in the crotch region 16 when the absorbent article 10, 210 is in a relaxed configuration, as shown in FIG. 1. The containment flaps 50, 52 can comprise a tacked region 71 in either or both of the front waist region 12 and the back waist region 14 where the protruding portion 66 is coupled to the body-facing surface 19 of the chassis 11.

[0075] It is contemplated that the containment flaps 50, 52 can have various configurations and shapes, and can be constructed by various methods. For example, Figure 5 The containment flaps 50, 52 of FIG. 1 depict vertical containment flaps 50, 52 having a tacked region 71 in both the front waist region 12 and the back waist region 14 where the protruding portion 66 of each containment flap 50, 52 is tacked into the body-side liner 28 toward or away from the longitudinal axis 29 of the absorbent article 10, 210. However, the containment flaps 50, 52 can include a tacked region 71 where the protruding portion 66 of each of the containment flaps 50, 52 is folded back on itself and coupled to itself and the body-side liner 28 in a “C-shaped” configuration, as is known in the art and described in U.S. Patent No. 5,895,382 to Robert L. Popp et al. As yet another alternative, it is contemplated that the containment flaps 50, 52 can be constructed in a “T-shaped” configuration, such as described in U.S. Patent No. 9,259,362 to Robert L. Popp et al. Such configurations can also include a tacked region 71 in either or both of the front waist region 12 and the back waist region 14, respectively. Of course, other configurations of containment flaps 50, 52 can be used in the absorbent article 10, 210 and still be within the scope of the present disclosure.

[0076] Leak-proof flaps 50, 52 may include one or more flap elastic members 68, such as Figure 5 The two elastic strands of the flaps are depicted. Suitable elastomeric materials for the flap elastic members 68 may include sheets, strands, or strips of natural rubber, synthetic rubber, or thermoplastic elastomers. Of course, although two elastic members 68 are shown in each leak-proof flap 50, 52, it is conceivable that the leak-proof flaps 50, 52 may be configured to have one, three, or more elastic members 68. Alternatively or otherwise, the leak-proof flaps 50, 52 may be made of materials that inherently exhibit elastomeric properties.

[0077] like Figure 5 The elastic member 68 shown may have two strands of elastomeric material that extend longitudinally in the protrusions 66 of the leak-proof flaps 50, 52, spaced generally parallel to each other. When in an elastically contractible state, the elastic member 68 may be located within the leak-proof flaps 50, 52, causing the strands to contract in the longitudinal direction 30, wrinkling and shortening the protrusions 66 of the leak-proof flaps 50, 52. Therefore, when the absorbent article 10 is in a relaxed configuration, with the leak-proof flaps 50, 52 in a generally upright orientation, the elastic member 68 may bias the protrusions 66 of the leak-proof flaps 50, 52 away from the body-facing surface 45 of the absorbent assembly 44, particularly in the crotch area 16 of the absorbent articles 10, 210.

[0078] During the manufacture of leak-proof flaps 50, 52, at least a portion of the elastic member 68 may be bonded to the leak-proof flaps 50, 52 as it elongates. The elongation percentage of the elastic member 68 may be, for example, from 110% to 350%. In one embodiment, the elastic member 68 may be coated with adhesive when it has elongated to a predetermined length before being attached to the leak-proof flaps 50, 52. In the stretched state, the length of the elastic member 68 to which the adhesive is attached provides a movable flap elastic region 70 in the leak-proof flaps 50, 52, such as... Figure 2As indicated, the flap elastic region will wrinkle when the absorbent article 10 is relaxed. The active flap elastic region 70 of the leak-proof flaps 50, 52 may have a longitudinal length less than the length of the absorbent articles 10, 210. In this exemplary method of attaching the elastic member 68 to the leak-proof flaps 50, 52, the uncoated portion of the elastic member 68 will retract after the elastic member 68 and the absorbent article 10 are cut during manufacturing to form a single absorbent article 10. As described above, when the absorbent articles 10, 210 are in a relaxed state, the relaxation of the elastic member 68 in the active flap elastic region 70 can cause each leak-proof flap 50, 52 to wrinkle and cause the protruding portion 66 of each leak-proof flap 50, 52 to extend away from the body-facing surface 19 of the substrate 11 (e.g., the body-facing surface 45 of the absorbent assembly 44, or the body-facing surface 56 of the body side liner 28), as Figure 5 As depicted in the text.

[0079] Of course, the resilient member 68 may be bonded to the leak-proof flaps 50, 52 in a variety of other ways known to those skilled in the art to provide a movable flap resilient area 70, which is within the scope of this disclosure. In addition, the movable flap resilient area 70 may be shorter or longer than depicted herein, including extending to the front waist edge 22 and the rear waist edge 24, which is still within the scope of this disclosure.

[0080] Leg elastic components:

[0081] Leg elastic members 60, 62 can be secured to the outer cover 26, for example, at a generally transversely inward location on the longitudinal side edges 18 and 20 of the absorbent articles 10, 210, by bonding them to the outer cover with a laminate adhesive. Leg elastic members 60, 62 can form elastic leg cuffs to further aid in containing bodily exudates. In one embodiment, leg elastic members 60, 62 can be disposed between the inner and outer layers (not shown) of the outer cover 26 or between other layers of the absorbent article 10, for example, between the base portion 64 of each leak-proof flap 50, 52 and the body-side lining 28 (e.g., Figure 5 (As depicted herein), between the base portion 64 of each leak-proof flap 50, 52 and the outer covering 26, or between the body side lining 28 and the outer covering 26. Leg elastic members 60, 62 may be one or more elastic components near each longitudinal side edge 18, 20. For example, each leg elastic member 60, 62 as shown herein comprises two elastic strands. A wide variety of elastomeric materials can be used for the leg elastic members 60, 62.

[0082] Suitable elastomeric materials may comprise sheets, strands, or strips of natural rubber, synthetic rubber, or thermoplastic elastomers. The elastomeric material may be stretched and fixed to a substrate, fixed to a corrugated substrate, or fixed to a substrate and then elastically treated or contracted, for example by applying heat, such that an elastic recoil force is imparted to the substrate. Furthermore, it is conceivable that in some embodiments, the leg elastic members 60, 62 may be formed with leak-proof flaps 50, 52 and then attached to the substrate 11. Of course, the leg elastic members 60, 62 may be omitted from the absorbent articles 10, 210 without departing from the scope of this disclosure.

[0083] Waist leak-proof components:

[0084] In one embodiment, the absorbent articles 10, 210 may have one or more waist leak-proof members 54. One or more waist leak-proof members 54 may be disposed in the lower back area 14, such as... Figures 1-5 As shown in the diagram. Generally, a lumbar leak-proof member 54 can help contain and / or absorb bodily excretions (especially low-viscosity feces) and is therefore preferably located in the lower back region 14. In some embodiments, the absorbent articles 10, 210 may have a lumbar leak-proof member 54 disposed in the anterior lumbar region 12. The lumbar leak-proof member 54 in the anterior lumbar region 12 can help contain and / or absorb bodily excretions, such as urine, in the anterior lumbar region 12. Although not as common as in the lower back region 14, in some cases feces may also diffuse into the anterior lumbar region 12, so a lumbar leak-proof member 54 disposed in the anterior lumbar region 12 can also help contain and / or absorb bodily excretions. In other embodiments, the absorbent articles 10, 210 may have a lumbar leak-proof member 54 in both the lower back region 14 and the anterior lumbar region 12.

[0085] A lumbar leak-proof component 54 may be disposed on the body-facing surface 45 of the absorbent assembly 44. In some embodiments, such as in Figures 1-2 and Figure 5 In the illustrated embodiment, the waist leak-proof member 54 may be disposed on the body-facing surface 56 of the body side lining 28. However, in some embodiments, such as in Figure 4 In the absorbent product 210, the waist leak-proof component 54 can be provided on the body-facing surface 58 of the back waist piece 15.

[0086] The waistline leak-proof member 54 may include a first longitudinal side edge 72 and a second longitudinal side edge 74. The first longitudinal side edge 72 may be opposite to the second longitudinal side edge 74. The distance between the first longitudinal side edge 72 and the second longitudinal side edge 74 may define the width 51 of the waistline leak-proof member 54 in the transverse direction 32, such as... Figure 2 As shown in the image.

[0087] like Figure 2 and 5As shown, the waist leak-proof member 54 can be configured such that the first longitudinal side edge 72 is laterally outward from the proximal end 64a of the base portion 64 of the leak-proof wing 50. Similarly, the waist leak-proof member 54 can be configured such that the second longitudinal side edge 74 is laterally outward from the proximal end 64a of the base portion 64 of the leak-proof wing 52. The waist leak-proof member 54 can be configured such that the width 51 of the waist leak-proof member 54 can be greater than the lateral distance between the longitudinally extending fold lines 25a, 25b, as shown. Figure 2 and Figure 4 As shown in the image.

[0088] The waist leak-proof member 54 may further include a proximal portion (not shown) and a distal portion 78. The proximal portion may be connected to the body-facing surface 19 of the substrate 11 (e.g., the body-facing surface 45 of the absorbent assembly 44, or the body-facing surface 56 of the body side lining 28), while the distal portion 78 of the waist leak-proof member 54 may move freely relative to the substrate 11 and the absorbent assembly 44 when the absorbent articles 10, 210 are in a relaxed configuration, such as... Figure 5 As shown in the diagram. When the waist leak-proof member 54 is in a relaxed configuration, the distal portion 78 extends vertically away from the substrate 11 and the absorbent assembly 44, this vertical direction being perpendicular to the plane defined by the longitudinal axis 29 and the transverse axis 31. A fold 79a separates the proximal and distal portions 78 of the waist leak-proof member 54. As used in this context, the fold 79a separates the proximal and distal portions 78 because the fold 79a defines the transition between the proximal and distal portions 78.

[0089] In some embodiments, the proximal portion of the lumbar leak-proof member 54 may be attached to the body-facing surface 56 of the body side lining 28. In other embodiments, the proximal portion of the lumbar leak-proof member 54 may be attached to the body-facing surface 58 of the rear lumbar panel 15. The proximal portion may be attached to the body-facing surface 45 by adhesive, pressure bonding, ultrasonic bonding, thermal bonding, or a combination thereof.

[0090] Since the distal portion 78 of the waist containment member 54 is free to move relative to the absorbent assembly 44 when the absorbent article 10, 210 is in the relaxed configuration, the distal portion 78 can help provide a containment pouch 82 when the absorbent article 10, 210 is in the relaxed configuration. The containment pouch 82 can help provide a barrier to contain and / or absorb body exudates. The containment pouch 82 can be particularly beneficial to contain and / or absorb low viscosity feces, which can be common for young children. The first longitudinal side edge 72 can be disposed laterally outward from the proximal end 64a of the base portion 64 of the containment flap 50, and thus, the containment pouch 82 can extend laterally outward from the proximal end 64a of the containment flap 50. Similarly, the second longitudinal side edge 74 can be disposed laterally outward from the proximal end 64a of the base portion 64 of the containment flap 52, and thus, the containment pouch 82 can extend laterally outward from the proximal end 64a of the containment flap 52. Such a configuration provides the waist containment member 54 with a spacious containment pouch 82 to contain and / or absorb body exudates.

[0091] To help prevent lateral flow of body exudates contained by the containment pouch 82 of the waist containment member 54, the distal portion 78 of the waist containment member 54 can be bonded to the proximal portion of the waist containment member 54 and / or the body-facing surface 19 of the backsheet 11 near the first longitudinal side edge 72 and the second longitudinal side edge 74, respectively. For example, Figure 5 Depicted are pinning zones 84 at which the distal portion 78 of the waist containment member 54 can be bonded to the proximal portion of the waist containment member 54 and / or the body-facing surface 19 of the backsheet 11.

[0092] In preferred embodiments, the waist containment member 54 can include at least one elastic member, and in further embodiments even more elastic members. In general, the elastic member(s) can span substantially from the first longitudinal side edge 72 to the second longitudinal side edge 74 of the waist containment member 54. The elastic member(s) can be disposed in the distal portion 78 of the waist containment member 54, and preferably near the free edge 88 of the distal portion 78 of the waist containment member 54.

[0093] A wide variety of elastomeric materials can be used for the elastic member(s) in the waist containment member 54. Suitable elastomeric materials can include sheets, strands, or ribbons of natural rubber, synthetic rubber, elastic foams, or thermoplastic elastomeric materials, such as films. The elastomeric materials can be stretched and secured to the substrate forming the waist containment member 54, secured to the pleated substrate, or secured to the substrate and then elastically or contractively set, such as by the application of heat, so that an elastic retractive force is imparted to the substrate forming the waist containment member 54.

[0094] The waist containment member 54 can be provided to be coupled to the chassis 11 by being placed over or under the containment flaps 50, 52. More specifically, the waist containment member 54 can be provided on the body-facing surface 19 of the chassis 11 such that the proximal portion of the waist containment member 54 is disposed over the respective base portions 64 of the first and second containment flaps 50, 52. Alternatively, the waist containment member 54 can be provided on the body-facing surface 19 of the chassis 11 such that the proximal portion of the waist containment member 54 is disposed under the respective base portions 64 of the first and second containment flaps 50, 52. Both of these configurations can provide advantages that facilitate the waist containment member 54 to function to contain and / or absorb body exudates.

[0095] In the case where the proximal portion of the waist containment member 54 is disposed over the base portions 64 of the containment flaps 50, 52, the containment flaps 50, 52 can have an active flap elastic region 70 that longitudinally overlaps the distal portion 78 of the waist containment member 54 when the absorbent article 10 is in the stretched, laid-flat configuration, such as shown in FIG. 1. Figure 2 Additionally or alternatively, the tacking region 71 can not extend from the back waist edge 24 to the free edge 88 of the distal portion 78 of the waist containment member 54, such as shown in FIG. 2. Figure 2 Additionally or alternatively, the tacking region 71 can not extend from the back waist edge 24 to the free edge 88 of the distal portion 78 of the waist containment member 54, such as shown in FIG. 2.

[0096] In the case where the proximal portion of the waist containment member 54 is disposed under the base portions 64 of the containment flaps 50, 52, the tacking region 71 of the projection portion 66 of each of the containment flaps 50, 52 can longitudinally overlap the distal portion 78 of the waist containment member 54. In some of these embodiments, the tacking region 71 of the projection portion 66 of each of the containment flaps 50, 52 can extend to the free edge 88 of the waist containment member 54 to further facilitate the containment of exudates in the containment pocket 82 created by the waist containment member 54.

[0097] The waist leak-proof component 54 can be composed of a variety of materials. In a preferred embodiment, the waist leak-proof component 54 may be composed of a spunbond-meltblown-spunbond (“SMS”) material. However, it is contemplated that the waist leak-proof component 54 may be composed of other materials, including but not limited to spunbond-film-spunbond (“SFS”) materials, bonded carded web (“BCW”) materials, or any nonwoven material. In some embodiments, the waist leak-proof component 54 may be composed of a laminate of more than one of these exemplary materials or other materials. In some embodiments, the waist leak-proof component 54 may be composed of a liquid-impermeable material. In some embodiments, the waist leak-proof component 54 may be composed of a material coated with a hydrophobic coating. The basis weight of the material forming the waist leak-proof component 54 may vary; however, in a preferred embodiment, where the elastic member 86 is not included in the waist leak-proof component 54, the basis weight may be between 8 gsm and 120 gsm. The basis weight of the material constituting the waist leak-proof component 54 is more preferably between 10 gsm and 40 gsm, and even more preferably between 15 gsm and 25 gsm.

[0098] Fastening system:

[0099] In one embodiment, the absorbent article 10 may include a fastening system. The fastening system may include one or more rear fasteners 91 and one or more front fasteners 92. Figure 1 and Figure 2 The illustrated embodiment depicts an embodiment with a front fastener 92. Multiple parts of the fastening system may be included in the front waist area 12, the rear waist area 14, or both.

[0100] Fastening systems can be configured to, for example Figure 1 The shown fastened state secures the absorbent article 10 around the wearer's waist and helps maintain the absorbent article 10 in place during use. In one embodiment, as known in the art, the rear fastener 91 may comprise one or more materials bonded together to form a composite earpiece. For example, the composite fastener may be made of, for example, Figure 2 It consists of the tensioning component 94, the nonwoven carrier or hook 96, and the fastening component 98 as marked in the diagram. Figure 5 As shown, in some embodiments, the waist leak-proof member 54 may extend to the rear fastener 91. In some embodiments, the waist leak-proof member 54 may be directly or indirectly connected to the tension member 94 of the rear fastener 91. In some embodiments, the waist leak-proof member 54 may extend to the longitudinal side edges 18, 20 of the absorbent articles 10, 210.

[0101] Absorbing entity:

[0102] The absorbent body 34 can be suitably constructed to be substantially compressible, conformable, pliable, non-irritating to the wearer's skin, and capable of absorbing and retaining liquid body exudates. The absorbent body 34 can be manufactured in a wide variety of sizes and shapes (for example, rectangular, trapezoidal, T-shape, I-shape, hourglass shape, etc.) and from a wide variety of materials. The size and absorbent capacity of the absorbent body 34 should be compatible with the size of the intended wearer (infant to adult) and the liquid loading imparted by the intended use of the absorbent article 10, 210. The absorbent body 34 can have a length and width that can be less than or equal to the length and width of the absorbent article 10, 210.

[0103] In one embodiment, the absorbent body 34 can be constructed of absorbent materials such as fibrous absorbent materials and / or superabsorbent materials, binder materials, surfactants, selected hydrophobic and hydrophilic materials, pigments, lotions, odor control agents, and the like, as well as combinations thereof. In one embodiment, the absorbent body 34 can be a matrix of cellulosic fluff and superabsorbent material. In another embodiment, the absorbent material of the absorbent body 34 can include only superabsorbent material. In one embodiment, the absorbent body 34 can be constructed of a single layer of material, or in the alternative, can be constructed of two or more layers of material.

[0104] When composed at least partially of fibrous materials, various types of wettable, hydrophilic fibers can be used in the absorbent body 34. Examples of suitable fibers include: natural fibers; cellulosic fibers; synthetic fibers composed of cellulose or cellulose derivatives, for example, rayon; inorganic fibers composed of a material that is inherently wettable, for example, glass fibers; synthetic fibers made from inherently wettable thermoplastic polymers, for example, specific polyester or polyamide fibers, or synthetic fibers made from non- wettable thermoplastic polymers, for example, polyolefin fibers that have been made wettable by suitable means. Fibers can be made wettable by treating them with a surfactant, treatments with silica, treatments with a material that has a suitable wettable portion and is not readily removed from the fiber, or by sheathing the non- wettable hydrophobic fiber with a wettable polymer during or after fabrication of the fiber.

[0105] When composed at least partially of superabsorbent materials, such superabsorbent materials can be selected from natural, synthetic, and modified natural polymers and materials. The superabsorbent materials can be inorganic materials, for example, silica gels, or organic compounds, such as crosslinked polymers.

[0106] If a spacer layer 48 is present, the absorbent body 34 can be disposed on the spacer layer 48 and superposed over the outer cover 26. The spacer layer 48 can be bonded to the outer cover 26, for example, by an adhesive bond. In some embodiments, the spacer layer 48 can not be present, and the absorbent body 34 can directly contact the outer cover 26 and can be directly bonded to the outer cover 26. However, it should be understood that the absorbent body 34 can be in contact with the outer cover 26 but not bonded to the outer cover, and remain within the scope of the present disclosure. In one embodiment, the outer cover 26 can be comprised of a single layer, and the absorbent body 34 can be in contact with the single layer of the outer cover 26. In one embodiment, at least a portion of a layer such as, but not limited to, the fluid transfer layer 46 and / or the spacer layer 48 can be positioned between the absorbent body 34 and the outer cover 26, such as Figure 5 is shown in FIGS. 10A-10B. The absorbent body 34 can be bonded to the fluid transfer layer 46 and / or the spacer layer 48.

[0107] According to some aspects of the present disclosure, the absorbent body 34 or at least one component of the absorbent body 34 can include an absorbent structure 101, as described in more detail with respect to Figures 9A-9C and 10A-10B. Figure 10B In some embodiments, the absorbent structure 101 can be the absorbent body 34, such as the absorbent body shown with respect to Figures 1-5 In other embodiments, the absorbent structure 101 can include only a portion of the absorbent body 34. For example, the absorbent structure 101 can be housed within the absorbent body 34 along with other materials, such as one or more web materials and / or additional absorbent materials. Such other materials, along with the absorbent structure 101 (collectively forming the absorbent body 34) can generally be identified as part of the absorbent body 34 by inclusion beneath the fluid transfer layer 46, which in different embodiments can or can not wrap around the side edges of the absorbent body 34. In contrast, the absorbent body 34 and the fluid transfer layer 46 disposed between the spacer layer 48 or the outer cover 26 and the body side liner 28 can together constitute the absorbent system of the article 10, 210.

[0108] In at least some embodiments, the absorbent material content of the absorbent structure 101 can primarily include superabsorbent material, by weight of the absorbent material of the absorbent structure 101. For example, the absorbent material content of the absorbent structure 101 can include greater than 80% superabsorbent material, greater than 85% superabsorbent material, greater than 90% superabsorbent material, greater than 95% superabsorbent material, by weight of the absorbent material of the absorbent structure 101, or can even include 100% superabsorbent material. In such embodiments, the remaining absorbent material content can include fibrous absorbent material, such as cellulose fibers, or any other suitable absorbent material.

[0109] The absorbent structure 101 according to the present disclosure can be formed according to the processes disclosed herein, such asFigures 6-8 The processes 300, 400 are described in greater detail below. Such absorbent structures 101 can advantageously provide greater thinness, flexibility, superabsorbent material capture, liner integrity than absorbent structures formed by different processes and / or including different materials or different relative amounts of materials. Although Figures 1-5 Diaper absorbent articles 10, 210 are described in detail, it should be understood that the absorbent structures 101 of the present disclosure can be used in any absorbent article, including but not limited to diapers, adult incontinence articles, training pants, larger child pants, swim pants, feminine hygiene products (including but not limited to sanitary napkins or sanitary pants), medical garments, surgical pads and bandages, other personal care or health care garments, and the like.

[0110] Figure 6 is an exemplary schematic of an absorbent structure formation process 300. The process 300 can include unwinding a web material 303 and moving the web material 303 in the machine direction 330. In some exemplary embodiments, an adhesive applicator 305 can apply adhesive 306 to the web material 303. The adhesive applicator 305 can pneumatically or by various coating methods (or any other suitable coating method) apply the adhesive 306 to the web material 303 in the form of dots, beads, swirls, or any other suitable pattern. It should be noted, however, that the adhesive applicator 305 and adhesive 306 can be optional and not present in other embodiments. Thus, in such embodiments, no adhesive 306 is placed onto the web material 303.

[0111] In either case, the web material 303 can continue to advance in the machine direction 330 to the absorbent material deposition station 302. At the absorbent material deposition station 302, the superabsorbent material 317 is mixed with one or more adhesives 308, 310 prior to being deposited onto the web material 303 (e.g., in the mixing zone 312) and ultimately onto the web material 303.

[0112] The superabsorbent material 317 flows out of the hopper 313 and through the chute 315 to the web material 303. The hopper 313 can be a bulk solids pump or feeder configured to maintain consistent flow of the superabsorbent material 317 through the absorbent material deposition station 302. The flow rate at which the superabsorbent material 317 flows out of the hopper 313 can be adjusted such that the hopper 313 can deliver different amounts of superabsorbent material 317, thereby creating different basis weights of superabsorbent material 317 in the finished absorbent structure 101. Such basis weight differences in the superabsorbent material 317 can allow the formed absorbent structure 101 to be used for different absorbent end uses, such as for diapers, feminine products, adult care garments, bandages, and the like.

[0113] The chute 315 has a chute end 354 (as Figure 7The chute end is shown oriented in a vertical direction 332 such that the superabsorbent material 317 (shown as individual particles 318 in Figure 7 the absorbent material deposition station 302. As used herein, the vertical direction 332 is used to denote a direction that is perpendicular to the web material 303. The machine direction 330 can be defined as a direction that is parallel within the web material 303, and thus can be perpendicular to the vertical direction 332. In embodiments in which the web material 303 is oriented in a horizontal direction with respect to gravity (e.g., perpendicular to the direction of gravity), the vertical direction 332 can be substantially aligned with respect to gravity. However, in other embodiments, the vertical direction 332 can be angled with respect to gravity, such as an angle that differs from the vertical by up to 25 degrees can be suitable for the vertical direction 332. Thus, in such embodiments, the superabsorbent material 317 can be falling toward the web material 303, the direction of which includes components in the vertical direction 332 and the machine direction 330 (or possibly opposite the machine direction 330).

[0114] In addition to this, regardless of the orientation of the vertical direction 332 with respect to gravity, the chute 315 can be further oriented in a non-perpendicular manner with respect to the web material 303. For example, the chute end 354 can be oriented perpendicularly with respect to the web material 303 (as shown in FIG. 3A), or can be oriented to form an angle with respect to a direction that is perpendicular to the web material 303 that is greater than 0 degrees and less than 25 degrees. Figure 7

[0115] Generally, the amount of superabsorbent material 317 supplied by the absorbent material deposition station 302 can be configured to result in the absorbent structure 101 including superabsorbent material 317 disposed at an amount between 50 gsm and 1000 gsm, or between 100 gsm and 1000 gsm, or between 150 gsm and 1000 gsm, or between 200 gsm and 800 gsm, or between 250 gsm and 800 gsm, or between 300 gsm and 700 gsm, or between 350 gsm and 700 gsm, or between 400 gsm and 700 gsm, or between 450 gsm and 700 gsm, or between 500 gsm and 700 gsm, or between 400 gsm and 600 gsm, or between 500 gsm and 600 gsm. Such superabsorbent material 317 basis weight values for the absorbent structure 101 can be particularly suitable for absorbent garments and feminine hygiene products. However, further absorbent structures 101 that can be formed in accordance with aspects of the present disclosure can have even smaller basis weights of superabsorbent material 317, such as between 5 gsm and 50 gsm, or between 5 gsm and 30 gsm, or between 10 gsm and 30 gsm. ​

[0116] Chute opening 354 can have an opening width 356 in the machine direction 330 (as measured where the superabsorbent material 317 exits the chute 315). The opening width 356 can be between 2 mm and 30 mm, or between 5 mm and 25 mm, or between 5 mm and 20 mm, or between 7 mm and 15 mm. More specifically, when the amount of superabsorbent material 317 deposited by the absorbent material deposition station 302 is between 50 gsm and 300 gsm, an opening width 356 of between 2 mm and 10 mm is preferred. Conversely, when the amount of superabsorbent material 317 deposited by the absorbent material deposition station 302 is between 300 gsm and 500 gsm, an opening width 356 of between 10 mm and 14 mm is preferred, and when the amount of superabsorbent material 317 deposited by the absorbent material deposition station 302 is between 500 gsm and 1000 gsm, an opening width 356 of between 14 mm and 20 mm is preferred.

[0117] The combination of these features (gravity feed method and chute opening width 356) can help to create a“sheet” or“stream” of superabsorbent material 317 that flows toward the web material 303. A particular width 356 can help to ensure that the stream 319 of superabsorbent material 317 has sufficient width and / or density (particularly at the point where the adhesive 308 and / or 310 contacts the stream 319), which can allow the adhesive 308 and / or 310 to better penetrate the stream 319 and mix with the superabsorbent material 317. These configurations can help to drive beneficial performance of the resulting absorbent structure 101, as described in more detail below. In some further embodiments, an air stream or air curtain can be used to help shape the stream 319 and / or maintain a desired width and / or density of the stream. In such embodiments, the superabsorbent material 317 can be directed toward the web material 303 somewhat more quickly than by gravity alone, but such embodiments can be considered to still include a gravity feed system, as the superabsorbent material 317 is not pneumatically or otherwise pushed out of the end of the chute 354.

[0118] As the superabsorbent material 317 falls toward the web material 303, the adhesive applicator 307 and / or 309 can spray the adhesive 308 and / or 310 toward the falling superabsorbent material 317. The adhesive 308 and / or 310 mixes with the falling superabsorbent material 317 before the mixture of superabsorbent material 317 and adhesive 308 and / or 310 is deposited onto the web material 303. Figure 7 is a close-up schematic view of the absorbent material deposition station 302, showing more detail regarding the adhesive applicator 307 and / or 309, adhesive 308 and / or 310.

[0119] The amount of adhesive 308 and / or 310 applied by the adhesive applicator 307 and / or 309 can generally be applied at an add-on percentage of less than 7%, or less than 6%, or less than 5%, or less than 4%, or less than 3%, or less than 2%. In other embodiments, the add-on percentage can be between 2% and 7%, or between 3% and 7%, or between 4% and 7%, or between 5% and 7%, or between 6% and 7%. As used herein, the term "add-on" amount or percentage is the added amount of the material such that the resulting weight of the material within the absorbent structure 101 has the desired relationship to the weight of the absorbent material within the absorbent structure 101. As one illustrative example, in the case where the superabsorbent material 317 is disposed in the absorbent structure 101 at a basis weight of 500 gsm, and in the case where the adhesive 308 and / or 310 is applied at an add-on rate of 5%, the resulting basis weight of the adhesive 308 and / or 310 in the formed absorbent structure would be 25 gsm (5% of 500 gsm).

[0120] As described above, in some embodiments, the absorbent material deposition station 302 can include two adhesive applicators 307 and 309. The first adhesive applicator 307 can be positioned upstream (relative to the process direction 330) of the chute 315, while the second adhesive applicator 309 can be positioned downstream of the chute 315. The superabsorbent material 317 can form a stream 319 of superabsorbent material 317 as it falls toward the web material 303. In the case where the adhesive applicator 307 is positioned on the upstream side of the chute 315, the adhesive applicator 307 is configured to spray the first adhesive 308 at a first side 352 of the stream 319 of superabsorbent material 317.

[0121] The adhesive applicator 307 can be configured to spray the first adhesive 308 such that the first adhesive 308 contacts the first side 352 of the stream 319 of superabsorbent material 317 along a portion of the stream 319 having a length 363 along the length 363 of the stream 319. In some embodiments, the length 363 can be insignificant as the first adhesive 308 can be sprayed as a stream with minimal to no spread. However, in other embodiments, the first adhesive 308 can have some spread, and thus the length 363 can be between 2 mm and 10 mm, or between 2 mm and 6 mm, or between 2 mm and 4 mm.

[0122] To allow the first adhesive 308 sufficient time to mix with the stream 319 of superabsorbent material 317 before the mixture of first adhesive 308 and superabsorbent material 317 is deposited onto the web material 303, the first adhesive 308 can generally contact the stream 319 at a first contact point located a distance 361 from the web material 303. The distance 361 can be between 4 mm and 40 mm, or between 4 mm and 35 mm, or between 5 mm and 30 mm, or between 6 mm and 25 mm. In cases where the first adhesive 308 is sprayed in a diffuse manner and contacts the stream 319 along a length 363, the first contact point is measured relative to the center of the length 363 along which the first adhesive 308 contacts the stream 319, and thus the distance 361 is measured.

[0123] To achieve such a distance 361, the nozzle 321 can be positioned at a distance 355 from the web material 303 and a distance 351 from the chute 315. These distances 355, 351 can be adjusted to achieve the desired distance 361. As some non-limiting examples, the distance 355 can generally be between 5 mm and 40 mm, or between 10 mm and 30 mm. In comparison, the chute 315 can be positioned at a distance 359 from the web material 303. The distance 359 can be between 50 mm and 90 mm, or between 60 mm and 80 mm, or between 70 mm and 80 mm. Distances 359 higher than 70 mm, or 80 mm, or 90 mm can result in undesirable spreading of the stream 319. Distances lower than 60 mm or 50 mm can result in insufficient space between the chute 315 and the web material 303 to allow sufficient mixing of the superabsorbent material 317 and the first adhesive 308 (or the second adhesive 310 described in more detail below).

[0124] It has further been discovered that an angle 369a at which the nozzle 321 is oriented relative to the machine direction 330 can be important to achieving a desired level of mixing between the first adhesive 308 and the stream 319. Preferably, the angle 369a can vary between 40 degrees and 80 degrees, or between 45 degrees and 75 degrees, or between 50 degrees and 70 degrees.

[0125] The adhesive applicator 309 can be similarly configured to the adhesive applicator 307. The adhesive applicator 309 can spray the second adhesive 310 such that the second adhesive 310 contacts the second side 354 of the stream 319 of superabsorbent material 317 along a portion of the stream 319, the portion having a length 365 along the stream 319. Thus, the length 365 can be insignificant as the second adhesive 310 can be sprayed as a stream with minimal to no spreading. In other embodiments, the second adhesive 310 can have some spreading such that the length 365 can vary between 2 mm and 10 mm, or between 2 mm and 6 mm, or between 2 mm and 4 mm.

[0126] To allow the second adhesive 310 sufficient time to mix with the stream 319 of superabsorbent material 317 before the mixture of the second adhesive 310 and the superabsorbent material 317 is deposited onto the web material 303, the second adhesive 310 can generally contact the stream 319 at a second point of contact on the stream 319 that is located a distance equal to the distance 367 plus the distance 361 from the web material 303. The distance 367 plus the distance 361 can generally be between 4 mm and 40 mm, or between 4 mm and 35 mm, or between 5 mm and 30 mm, or between 6 mm and 25 mm. In addition to this, in the case where the second adhesive 310 is sprayed in a diffuse manner and contacts the stream 319 along a length 365, the second point of contact and the distance 367 plus the distance 361 are measured relative to the center of the length 365 along which the second adhesive 310 contacts the stream 319 (if the first adhesive 308 contacts the stream 319 for an appreciable length 363, then relative to the center of the length 363).

[0127] It can be appreciated that the distance 361 and the distance 361 plus the distance 367 overlap within their preferred ranges. According to some preferred embodiments, the distance 361 is less than the distance 361 plus the distance 367. For example, it can be preferred that the applicator 307 is positioned closer to the web material 303 than the applicator 309. In such embodiments, the distance 361 can preferably be between 4 mm and 22 mm, or between 4 mm and 20 mm, or between 6 mm and 15 mm. The distance 361 plus the distance 367 can be between 5 mm and 15 mm, or between 6 mm and 13 mm, or between 6 mm and 11 mm greater than the distance 361, for example, the distance 367 can be between 5 mm and 15 mm, or between 6 mm and 13 mm, or between 6 mm and 11 mm. In such embodiments, the distance 367 can represent the spacing between the first point of contact of the first adhesive 308 with the stream 319 and the second point of contact of the second adhesive 310 with the stream 319.

[0128] It has been found that spraying the adhesive 308 and / or 310 at the stream 319 can cause the stream 319 to bend in the direction of the spray. Without being limited by theory, it is believed that the force of the adhesive 308 and / or 310 contacting the stream and / or the optional pattern of air supplied by the applicator 307 and / or 309 can cause such bending of the stream 319. Thus, where the first point of contact of the first adhesive 308 with the stream 319 is at a lower point than the second point of contact of the second adhesive 310 with the stream 319, the stream 319 can bend in the machine direction 330 in the machine 330 prior to being deposited onto the web material 303. Such bending of the stream 309 in the machine direction 330 helps to ensure smooth deposition of the mixture of superabsorbent material 317 and first adhesive 308 (and optional second adhesive 310), resulting in a more uniform mixture 320, which has many benefits in terms of capture and stabilization of the superabsorbent material 317, integrity of the resulting absorbent structure 101, and uniform distribution of the superabsorbent material 317 and first adhesive 308 (and optional second adhesive 310).

[0129] As with the nozzle 321, the nozzle 323 can be positioned at a distance 357 from the web material 303 and at a distance 353 from the chute 315 so as to achieve the desired distance 361 plus the distance 367. The angle 369b at which the nozzle 323 is oriented relative to the material web 303 can further be similar to the angle 369a. For example, the angle 369b can vary between 40 degrees and 80 degrees, or between 45 degrees and 75 degrees, or between 50 degrees and 70 degrees. In at least some embodiments, the angle 369a and the angle 369b can be the same, while in other embodiments, the angles 369a, 369b are different.

[0130] The applicators 307 and / or 309 can be preferably configured to spray the adhesive 308 and / or 310 in a substantially random pattern. It has been found that more random, irregular, or erratic spray patterns can yield better results in terms of performance of the absorbent structure 101, such as in terms of capture and stabilization of the superabsorbent material 317, integrity of the resulting absorbent structure 101, and uniformity of distribution of the superabsorbent material 317 and the adhesive 308 and / or 310. One such exemplary spray pattern is the Universal Spray Pattern produced by the nozzle available from Nordson Corporation (having headquarters at 28601 Clemens Road, Westlake, OH 44145 USA). However, in other embodiments, different adhesive spray patterns that are more regular and less random, but still considered to be random patterns, can be sufficient to produce an absorbent structure 101 having the desired performance properties. It can further be contemplated that some non-random spray patterns can also be sufficient to produce an absorbent structure 101 having the desired performance properties. TM Signature TM pattern. However, in other embodiments, different adhesive spray patterns that are more regular and less random, but still considered to be random patterns, can be sufficient to produce an absorbent structure 101 having the desired performance properties. It can further be contemplated that some non-random spray patterns can also be sufficient to produce an absorbent structure 101 having the desired performance properties.

[0131] Despite Figure 7 The diagram shows two adhesive applicators 307 and / or 309, but in some embodiments, the absorbent material deposition station 302 may include only one of adhesive applicators 307 and / or 309. Furthermore, although, as shown and described above, adhesive applicator 307 guides adhesive 308 to a first side 352 of the flow 319 (which is the upstream side of the flow 319), this first side is positioned closer to the web material 303 than adhesive applicator 309, this orientation is not required in all embodiments. For example, in a further embodiment, adhesive applicator 307 may be positioned further away from the web material 303 than adhesive applicator 309, while still being positioned on the upstream side of the flow 319. In any of these embodiments, the distances between the first contact point and the second contact point relative to each other and relative to the aforementioned web material may be reversed. In other words, distance 361 describes the distance between the second contact point and the fiber web material 303, while distance 361 plus distance 367 describes the distance between the first contact point and the fiber web material 303 (where distance 367 describes the distance between the first contact point and the second contact point).

[0132] As the web 303 passes through the absorbent material deposition station 302, a deposition mixture 320 is formed, consisting of adhesive 308 and / or 310 and superabsorbent material 317. In embodiments where adhesive 306 is sprayed onto the web material 303 using an adhesive applicator 305, adhesive 306 operates together with adhesive 308 and / or 310 to attach the superabsorbent material 317 to the web material 303. In embodiments where adhesive applicator 305 is not used, only adhesive 308 and / or 310 operate to attach the superabsorbent material 317 to the web material 303.

[0133] During deposition of the mixture 320, vacuum energy can optionally be applied to the web material 303. For example, the web material 303 can be supported by a forming surface, such as a forming belt or forming drum as is common in the art. Vacuum energy can be applied to the forming surface such that air is drawn through the forming surface from the side on which the web material 303 is located. Thus, the web material 303 is drawn to the forming surface as it falls toward the web material 303 due to the applied vacuum energy along with the mixture 320. Such vacuum energy can help control the spread of the mixture 320 as it falls toward the web material 303, thereby helping to form a relatively more uniform absorbent structure 101. It has been found that particularly high pressure differentials are preferred at the forming surface, higher and beyond typical pressure differentials in the art. For example, it can be preferred that the vacuum energy creates a pressure differential at the forming surface of greater than 0.25 m of water column. In further embodiments, it can be more preferred for even higher pressure differentials, such as greater than 0.35 m of water column, or greater than 0.5 m of water column, or greater than 0.65 m of water column (as measured at the forming surface).

[0134] The web material 324 can be further applied to the deposited mixture 320. In some embodiments, a binder applicator 325 can spray a binder 326 onto the web material 324 prior to the web material 324 being positioned onto the deposited mixture 320. It should be appreciated, however, that the binder applicator 325 is merely optional and can be absent in some embodiments. When present, the applied binder 326 can operate to more tightly couple the web material 324 to the deposited mixture 320 and / or further immobilize the superabsorbent material 317 within the formed absorbent structure.

[0135] According to some aspects of the present disclosure, the combination of the web material 303, the deposited mixture 320, and the web material 324 can be passed through one or more nip stations 327 to help compress these components together. Generally, the nip stations 327 can apply a pressure of 0.5 pounds per linear inch (PLI) (88 N / m) to 1.5 PLI (263 N / m), or 0.75 PLI (131 N / m) to 1.25 PLI (219 N / m) to the combination of the web material 303, the deposited mixture 320, and the web material 324. Such pressure helps to further join the deposited mixture to the web materials 303, 324. Although not required in all embodiments, it can be preferred that the nip stations 327 are positioned relatively close to the material deposition station 302 such that the binders 308 and / or 310 are still open when the combination of the web material 303, the deposited mixture 320, and the web material 324 pass through the nip stations 327.

[0136] After the one or more roll nip stations 327, the combination of web material 303, deposited mixture 320, and web material 324 can be passed to a cutting station 329 at which the lengths of web material 303, deposited mixture 320, and web material 324 are cut into individual absorbent structures 101. These individual absorbent structures 101 can then be combined into manufacturing processes for producing the various absorbent products described herein.

[0137] Figure 8 An exemplary schematic of an alternative absorbent structure formation process 400 is depicted. Process 400 is similar to process 300, with the difference being that process 400 employs two absorbent material deposition stations 302a, 302b. It has been found that using two absorbent material deposition stations 302a, 302b has some advantages over using a single absorbent material deposition station 302. For example, as the desired amount of deposited superabsorbent material 317 increases, the ability of a single absorbent material deposition station 302 to form absorbent structures 101 having desirable performance properties decreases. If the desired amount of deposited superabsorbent material 317 is too high, a single absorbent material deposition station 302 can not be able to form a mixture of superabsorbent material 317 and adhesive sufficient to immobilize the superabsorbent material 317, particularly at the desired low adhesive addition levels. For example, in such instances, the superabsorbent material acquisition properties of such formed absorbent structures 101 can be lower than desired.

[0138] Conversely, by employing two absorbent material deposition stations 302a, 302b, it can be possible to sufficiently immobilize the same desired amount of deposited superabsorbent material 317 such that the resulting absorbent structures 101 have the desired superabsorbent material acquisition values. In addition to this, employing two absorbent material deposition stations 302a, 302b can improve productivity even in instances of lower superabsorbent material 317 amounts and higher adhesive addition levels. Thus, in process 400, after the mixture of superabsorbent material 317 and adhesive 308 and / or 310 is deposited onto web material 303 at absorbent material deposition station 302a (which can be equivalent to absorbent material deposition station 302 of process 300), web material 303 and the deposited mixture of superabsorbent material 317 and adhesive 308 and / or 310 are moved to absorbent material deposition station 302b. Figure 6 and Figure 7 of process 300).

[0139] Similar to the absorbent material deposition station 302a, the absorbent material deposition station 302b can be configured to direct a second stream 331 of superabsorbent material 317 toward the web 303 and the mixture of deposited superabsorbent material 317 and adhesive 308 and / or 310. The absorbent material deposition station 302b can include adhesive applicators 333 and / or 335 that can spray adhesive 334 and / or 336 toward the second stream 331 of falling superabsorbent material 317. The adhesive 334 and / or 336 mixes with the falling superabsorbent material 317 before the mixture of the second stream 331 of superabsorbent material 317 and adhesive 334 and / or 336 is deposited onto the web material 303 and the previously deposited mixture of superabsorbent material 317 and adhesive 308 and / or 310.

[0140] According to some aspects of the present disclosure, the absorbent material deposition station 302b can include two adhesive applicators 333 and 335. With respect to the absorbent material deposition station 302b, a first adhesive applicator 333 (which can be the third adhesive applicator of the process 400) can be positioned upstream (relative to the process direction 330) of the chute 315 of the second deposition station 302b, while a second adhesive applicator 335 (which can be the fourth adhesive applicator of the process 400) can be positioned downstream of the chute 315 of the second deposition station 302b. The adhesive applicator 333 is configured to spray a first adhesive 334 (which can be the third adhesive of the process 400) at a first side of the second stream 331 of superabsorbent material 317. The adhesive applicator 335 is configured to spray a second adhesive 336 (which can be the fourth adhesive of the process 400) at a second side of the second stream 331 of superabsorbent material 317.

[0141] Generally, with respect to the absorbent material deposition station 302b Figure 7 The position, location, distance, and other features of the absorbent material deposition station 302 described, as well as optional components or features, can be the same as the absorbent material deposition station 302a. Likewise, the absorbent material deposition station 302b can be the same as or substantially similar to the absorbent material deposition station 302a. The absorbent material deposition station 302b can be positioned between 0.25 m and 3.0 m, or more preferably between 0.25 m and 2.0 m, or even more preferably between 0.25 m and 1.0 m.

[0142] Returning to the web materials 303 and 324, as Figure 6 and Figure 8As shown, the web material 324 may be coupled to a deposition mixture 320 of the superabsorbent material 317 and adhesives 308, 310, 334 and / or 336 to form the absorbent structure 101. According to some alternative embodiments of various aspects of this disclosure, the web material 324 may be completely omitted. In such embodiments, the web material 303 may be wide enough that after the mixture 320 is deposited onto the web material 303, the web material 303 wraps around the mixture 320 to form the absorbent structure 101.

[0143] Figures 9A-9C Different cross-sections of an exemplary absorbing structure 101 according to various aspects of this disclosure are depicted. (Representation) Figures 9A-9C The cross section is along Figure 8 Line 9-9 shows different configurations of mixture 320, web material 303, and web material 324 (if present).

[0144] Figure 9A An embodiment of the absorbent structure 101 of this disclosure, comprising web material 303 and web material 324, is depicted, wherein a mixture 320 is disposed between web material 303 and web material 324. Web material 303 and web material 324 may each have top surfaces 342 and 344 and bottom surfaces 343 and 345, respectively. According to... Figure 9A In some exemplary embodiments, the mixture 320 may be disposed on the top surface 342 of the web material 303 and the bottom surface 345 of the web material 324. In some embodiments of these embodiments, the absorbent structure 101 may further include a seam adhesive 346 disposed on the outside of the mixture 320 and bonding the bottom surface 345 of the web material 324 to the top surface 342 of the web material 303. Such a seam adhesive 346 may help seal the side edges 358a, 358b of the closed absorbent structure 101. However, it should be understood that such an adhesive 346 is not necessary in all embodiments, and many embodiments sufficiently capture the superabsorbent material 317 such that even without the seam adhesive 346, little or no superabsorbent material 317 may escape from the absorbent structure 101.

[0145] If present, joint adhesive 346 may be applied by an adhesive applicator before or after the deposition of mixture 320 (e.g., optional adhesive applicators 305 and / or 325 may apply joint adhesive 346). Alternatively, joint adhesive 346 may be applied during the deposition of mixture 320 by adhesive applicators 307, 309, 333, and / or 335, for example, if the adhesive spray from adhesive applicators 307, 309, 333, or 335 is wider than one or more flows of superabsorbent material 317. However, in other embodiments, absorbent structure 101 may not include any joint adhesive 346. In such embodiments, adhesives 308, 310, 334, and / or 336 are sufficient to bond web material 303 to web material 324.

[0146] Figure 9B Another embodiment of the absorbent structure 101 of this disclosure, comprising web material 303 and web material 324, is depicted, wherein a mixture 320 is disposed between web material 303 and web material 324. In this embodiment, with Figure 9A Conversely, in the alternative embodiment, instead of bonding the bottom surface 345 of the web material 324 to the top surface 342 of the web material 303, the top surface 344 of the web material 324 can be bonded to the top surface 342 of the web material 303. For example, the web material 324 can be at least partially wound around the mixture 320, sometimes referred to as C-winding, such that the bottom surface 345 of the web material 324 is positioned around a portion of a first side and a second side of the mixture 320. Figure 9B In the illustrated embodiment, web material 324 may be disposed between mixture 320 and web material 303, wherein web material 324 and web material 303 overlap. Although in other embodiments, web material 324 may be wound around mixture 320 and web material 303 such that web material 303 is disposed between mixture 320 and web material 324, wherein web material 324 and web material 303 overlap.

[0147] exist Figure 9B In the illustrated embodiment, the absorbent structure 101 may include a seam adhesive 346 that attaches the top surface 344 of the web material 324 to the top surface 342 of the web material 303 near the lateral edges of the absorbent structure 101. However, it should be understood that such a seam adhesive 346 is optional and may not be present in all embodiments. If present, the seam adhesive 346 may be applied, for example, by optional adhesive applicators 305 and / or 325, or by one or more of adhesive applicators 307, 309, 333, and / or 335.

[0148] Figure 9CAnother embodiment of the absorbent structure 101 of this disclosure, comprising only the web material 303, is depicted. In this embodiment, the web material 303 is wound around the mixture 320, for example, forming a C-shaped winding configuration. Figure 9C As shown, the web material 303 has web end portions 347 and 349. According to... Figure 9C In some exemplary embodiments, the web material 303 may be wound around the mixture 320 such that the web end portions 347 and 349 overlap each other. For example... Figure 9C As shown, this configuration may further include one or more seam adhesives 346 disposed between the web end portions 347 and 349 and bonding the web end portions 347 and 349 of material 303 together. However, such seam adhesives 346 are optional and may not be present in other embodiments. Figure 9C In a further embodiment, the web end portions 347 and 349 may be spaced apart from each other so that the web end portions 347 and 349 do not overlap. In such an embodiment, a portion of the mixture 320 may not be covered by the web material 303.

[0149] about Figures 9A-9C The exemplary absorbent structure 101 may have a top side 362 and a bottom side 364. However, it should be understood that these absorbent structures 101 can be used in any orientation. For example, in some cases, the described absorbent structure 101 may be placed in an absorbent article (such as article 10) with the top side 362 disposed closest to the body-facing surface 19. In other cases, the absorbent structure 101 may be placed in an absorbent article (such as article 10) with the bottom side 364 disposed closest to the body-facing surface 19.

[0150] When the web material 303 forms the top surface 362 of the absorbent structure 101 and is disposed closest to the body-facing surface 19, the web material 303 can be any suitable nonwoven material, such as bonded carded web, meltblown material, spunbond material, including spunbond and meltblown composite webs commonly referred to as SMS webs or SMMS webs, spunlace fabric materials, hydroentangled web materials, air-laid web materials, co-molded materials, or materials formed according to the mixing techniques used to form the above materials, such as spunbond-meltblown-spunbond materials or other similar materials. Typical basis weights of such web materials 303 can range from 8 gsm to 200 gsm, or from 10 gsm to 150 gsm, or from 10 gsm to 100 gsm. Alternatively, the web material 303 can be formed from wet-laid fiber materials (such as unwrinkled or wrinkled paper) or other sheet materials made of cellulose fibers. The web material 303 may further comprise a combination of nonwoven and fibrous materials, including fibrous pulp trapped on top of or between the nonwoven or wet-laid fibrous materials. In such embodiments, the fibrous pulp may be densified to form the web material 303 prior to its use in trapping the superabsorbent 317 and binders 308 and / or 310.

[0151] Regardless of any particular type of material, it has been found that the web material 303 should ideally have sufficient air permeability to allow a vacuum airflow through the web material 303, and in this vacuum airflow, at least partially entrain a flow 319 (and optionally, 331) of superabsorbent material 317 and adhesives 308 and / or 310 (and optionally, 334 and / or 336). For example, it has been found that the air permeability of the web material 303 should be greater than 25 standard cubic feet per minute (SCFM) of air (0.71 standard cubic meters per minute (SCMM)). In a further embodiment, it may be more preferable that the web material 303 has an air permeability greater than 50 SCFM (1.4 SCMM) or greater than 75 SCFM (2.1 SCMM). Such air permeability measurements can be consistent with standard industrial practices used to measure air permeability. According to some implementation schemes, such air permeability measurements can be performed using the Frazier Instruments LP air permeability tester (located in the office in Haggstown, Maryland), the Textest FX3300 air permeability unit (located in the office in Schwezenbach, Switzerland), or an equivalent test unit.

[0152] Likewise, in cases where the web material 303 forms the top surface 362 of the absorbent structure 101 and in cases where the top surface 362 is disposed closest to the body-facing surface 19, the fibers of the web material 303, or at least the surface fibers, desirably have sufficient wettability to allow fluid intake, fluid flow, and fluid distribution through the web material 303 to the superabsorbent material 317. In some embodiments, the wettability can come from the composition of the fibers. For example, the fibers forming the web material 303 can be inherently wettable fibers, including, for example, natural cellulosic fibers from cotton, wood, or other fibers. Other examples of inherently wettable fibers include reconstituted cellulose fibers, such as rayon. In further embodiments, the fibers forming the web material 303 can not be inherently wettable, but can be rendered wettable, such as by a surfactant treatment added to the fibers, or at least to the surface fibers. The surfactant treatment can be applied to at least the surface fibers in a continuous or discontinuous manner. In other embodiments, the surfactant treatment can be added internally to the fibers, which will eventually migrate to the surface of the fibers.

[0153] In cases where the web material 324 forms the bottom side 364 of the absorbent structure 101 and in cases where the bottom side 364 is disposed closest to the body-facing surface 19, the web material 324 can be any suitable nonwoven material, for example, any of the materials described with respect to the web material 303. In addition to this, the web material 324 can desirably have any of the same properties as the web material 303 described above. In cases where the web material 324 forms the bottom side 364 of the absorbent structure 101 and the top side 362 is closest to the body-facing surface 19, the web material 324 can also be any of the materials described above with respect to the web material 303, including having any of the properties and ranges thereof described.

[0154] The adhesive 308 and / or 310 can generally comprise a hot melt adhesive, and the nozzles 321, 323 can be configured to spray the adhesive 308 and / or 310 toward the stream 319 of superabsorbent material 317 such that the adhesive 308 and / or 310 forms adhesive filaments 316. Desirably, the adhesive 308 and / or 310 should have sufficient tack and cohesion. An exemplary suitable adhesive is TECHNOMELT DM 5402U adhesive available from Henkel Corporation, a company having an office in Rocky Hill, Connecticut. This suitable adhesive is a hot melt adhesive based on styrene block copolymer designed to have high cohesion and strong specific adhesion to provide good fixation of the superabsorbent material 317 in the absorbent structure under wet and dry conditions. It is generally further preferred that the adhesive 308 and / or 310 be non-water soluble to help maintain the positioning of the superabsorbent material 317 within the structure 101 after one or more liquid insults. It has been found that rubber-based adhesives can be preferred because they can produce structures 101 with performance superior to other adhesives such as standard construction adhesives or olefin-based adhesives.

[0155] Generally, the adhesive applicators 307 and / or 309 operate to spray the adhesive 308 and / or 310 such that the adhesive 308 and / or 310 forms adhesive filaments 316 that contact the stream 319. The adhesive applicators 307 and / or 309 can generally be configured to spray the adhesive 308 and / or 310 such that the adhesive 308 and / or 310 forms filaments 316 having a preferred diameter. It has been found that it can be preferred that the diameter of the filaments 316 be between 25 micrometers (microns) and 150 micrometers, or between 50 micrometers and 100 micrometers, or between 75 micrometers and 100 micrometers. These ranges of filament diameters have been shown to work well with superabsorbent materials 317 having the following particle diameters to provide beneficial performance characteristics for the structure 101.

[0156] While the above adhesive properties have been described with respect to the adhesive 308 and / or 310, if present, the adhesive 334 and / or 336 can have similar properties to those described above with respect to the adhesive 308 and / or 310. Likewise, if present, the applicator 333 and / or 335 can be configured to spray the adhesive 334 and / or 336 in a similar manner to the manner in which the adhesive applicator 307 and / or 309 is configured to spray the adhesive 308 and / or 310. For example, the diameter of the filament 316 formed from the adhesive 334 and / or 336 sprayed from the applicator 333 and / or 335 can be similar to the diameter of the filament 316 described above formed from the adhesive 308 and / or 310 sprayed from the applicator 307 and / or 309.

[0157] In addition to the above, it has been found that the size of the individual particles 318 of the superabsorbent material 317 can determine certain desirable properties of the absorbent structure 101 formed. For example, the particle size of the individual particles 318 can at least partially determine the integrity of the pad and the acquisition value of the superabsorbent material, particularly in combination with the structural features of the adhesive filament 316. For example, it has been found that good results are provided where the bulk superabsorbent material 317 has an average particle size of between 150 and 1000 micrometers (microns), particularly in combination with the diameter of the adhesive filament 316 described above. In such embodiments, it can be preferred that at least 50% of the mass of the bulk superabsorbent material 317 has a diameter greater than 180 microns. In other embodiments, it can be preferred that at least 60%, or at least 70%, or at least 80% of the mass of the bulk superabsorbent material 317 has a diameter greater than 180 microns. In further embodiments, it can be more preferred that at least 50% of the mass of the bulk superabsorbent material 317 has a diameter greater than 300 microns, or at least 60%, or at least 70%, or at least 80% of the mass of the bulk superabsorbent material 317 has a diameter greater than 300 microns.

[0158] When the average particle size of the bulk superabsorbent material 317 is too low (e.g., below 300 micrometers or below 180 micrometers), the formation and performance of structure 101 can be adversely affected. For example, such a small average particle size may affect the ability of the superabsorbent material 317 to fall from the chute 315 in a relatively uniform flow, resulting in a relatively less uniform superabsorbent material 317 and binders 308 and / or 310 (and optionally, 334 and / or 336). Furthermore, such a small average particle size may begin to approach the average diameter of the binder filaments 316, affecting both the capture of individual particles 318 by the binder filaments 316 and reducing absorption performance, as the binder filaments 316 will more easily prevent liquid from penetrating all portions of the individual particles 318. The quality of the particles in different portions of the bulk superabsorbent material 317 can be determined by any classification method known in the art. For example, it is well known that particles in different portions of the bulk superabsorbent material 317 with different sieve aperture sizes can be separated from bulk superabsorbent material 317 with different particle sizes using multiple sieves with different sieve aperture sizes. One particular method that can be used in this type of classification work is ASTM D1921–18, entitled “Standard Test Method for Particle Size of Plastic Materials (Sieve Analysis)”.

[0159] According to a further aspect of this disclosure, another way in which the deposition of mixture 320 may differ between absorbent material deposition stations 302a, 302b is that the widths of the superabsorbent material streams 319, 331 in the direction perpendicular to the machine direction 330, referred herein as the transverse machine direction 338, may differ. For example, one of the streams 319, 331 may be narrower than the other in the transverse machine direction 338, such that the produced absorbent structure 101 has partitioned basis weight regions of the superabsorbent material 317 (and binders 308, 310, 334 and / or 336). Figures 10A-10B Depicting along Figure 8 Different exemplary cross-sections of the absorber structure 101, taken along the midline 10-10, illustrate this partitioned mixture 320. Therefore, Figures 10A-10B The absorber structure 101 represents different exemplary absorber structures 101 produced by process 400, wherein the transverse widths of the superabsorbent material 317 flows 319, 331 are different, thus resulting in different widths of the deposited mixture 320 throughout the structure 101. It should be understood that all these embodiments described below with respect to depositing the mixture 320 with different transverse widths across the machine direction can be further combined with any of the foregoing embodiments, wherein the amount of superabsorbent material 317 and / or the amount of binders 308, 310, 334 and / or 336 differ between each absorbent material deposition station 302a, 302b.

[0160] Figure 10AAn exemplary cross-section of the absorbing structure 101 is depicted, having a total width 370, a central region 371 with a central region width 372, and side regions 373 with side region widths 374a, 374b. The central region width 372 is typically between 20% and 80% of the total width 370. In a more specific embodiment, the central region width 372 may be between 25% and 75% of the total width 370, or between 30% and 70%, or between 35% and 65%, or between 40% and 60%. Therefore, the side region widths 374a, 374b together are typically between 20% and 80% of the total width 370, equal to the required percentage of the total width 370, which, when added to the central region width 372, equals 100% of the total width 370. In some embodiments, the side region widths 374a, 374b may be equal to each other. Although in other embodiments, the side area widths 374a and 374b may differ from each other by more than 0% and less than 50% of the side area widths 374a and 374b having the larger value. As an illustrative example, the total width 370 may be 100 mm, the center area width 372 may be 60 mm, the side area width 374a may be 25 mm, and the side area width 374b may be 15 mm (e.g., 40% smaller than the side area width 374a having the larger value).

[0161] exist Figure 10A In the illustrated embodiment, the central area may have a central area height of 376, while the side areas 373 may have a side area height of 378. Figure 10A The orientations shown, heights 376 and 378, can be related to the basis weight of regions 372 and 373, particularly to the basis weight of the superabsorbent material 317 (and adhesives 308, 310, 334, and / or 336) within regions 371 and 373. Therefore, in Figure 10AIn some embodiments, where the height of the central region 376 is greater than the height of the side regions 378, the central region 371 may have a larger basis weight of superabsorbent material 317 (and adhesives 308, 310, 334 and / or 336) than the side regions 373. According to some embodiments of this disclosure, the basis weight of the superabsorbent material 317 in the side regions 373 may be 0% to 75% smaller than the basis weight of the superabsorbent material 317 in the central region 371. In more specific embodiments, the basis weight of the superabsorbent material 317 in the side regions 373 may be 10% to 70%, or 10% to 60%, or 10% to 50%, or 20% to 60%, or 30% to 60%, or 40% to 60% smaller than the basis weight of the superabsorbent material 317 in the central region 371. As an illustrative example, the central region 371 may have a basis weight of 500 gsm for the superabsorbent material 317, while the side regions 373 may have a basis weight of superabsorbent material 317 between 150 gsm and 450 gsm (using examples in which the basis weight of the superabsorbent material 317 in the side regions 373 is 10% to 70% smaller than that in the central region 371).

[0162] As previously described, to achieve the specific difference in the basis weight of the superabsorbent material 317 within the central region 371 and the side region 373, the trans-machine direction widths of the flows 319 and 331 may differ between the absorbent material deposition stations 302a and 302b. In some embodiments, the trans-machine direction width of the flow 319 may be smaller than the trans-machine direction width of the flow 331. In such embodiments, the absorbent material deposition station 302a including the flow 319 may contribute superabsorbent material 317 substantially only within the central region 371. Therefore, in such embodiments, the trans-machine direction width of the flow 331 may be greater than the trans-machine direction width of the flow 319, and the absorbent material deposition station 302b including the flow 331 may contribute superabsorbent material 317 to both the central region 371 and the side region 373. Of course, in other embodiments, the reverse can be true, where the trans-machine direction width of the flow 331 is smaller than the trans-machine direction width of the flow 319. Such embodiments can produce an appearance substantially similar to Figure 10A The structure shown is 101.

[0163] Figure 10B An exemplary cross-section of the absorption structure 101 having a central region 371 and side regions 373 is depicted. Figure 10B In the implementation plan, with Figure 10A The implementation scheme is the opposite, with the central area height of 376 being less than the side area height of 378. Therefore, in Figure 10B In one implementation, the basis weight of the superabsorbent material 317 in the side region 373 may be greater than that of the superabsorbent material 317 in the central region 371. The difference in basis weight between the central region 371 and the side region 373 can be similar to that between the two regions. Figure 10AThe difference (e.g., the basis weight of the superabsorbent material 317 in the center region 371 can be between 0% and 75% less than the basis weight of the superabsorbent material 317 in the side regions 373).

[0164] As previously described, to achieve the above-described particular difference in basis weight of the superabsorbent material 317 in the center region 371 and the side regions 373, the cross-machine direction width of the streams 319, 331 can differ between the absorbent material deposition stations 302a, 302b. In some embodiments, the cross-machine direction width of the stream 319 can be less than the cross-machine direction width of the stream 319. In such embodiments, the stream 319 can contribute superabsorbent material 317 substantially only in the center region 371. Thus, in such embodiments, the cross-machine direction width of the stream 331 can be greater than the cross-machine direction width of the stream 319 and contribute superabsorbent material 317 to both the center region 371 and the side regions 373. Of course, in other embodiments, it can be reversed, where the cross-machine direction width of the stream 331 is less than the cross-machine direction width of the stream 319. Such embodiments can result in a structure 101 that looks substantially similar to Figure 10A the structure 101 shown.

[0165] To achieve the above-described particular difference in basis weight of the superabsorbent material 317 in the center region 371 and the side regions 373, the cross-machine direction width of the streams 319, 331 can differ between the absorbent material deposition stations 302a, 302b. In some embodiments, the cross-machine direction width of the stream 319 can be less than the cross-machine direction width of the stream 319. In such embodiments, the stream 319 can contribute superabsorbent material 317 substantially only in the center region 371. Thus, in such embodiments, the cross-machine direction width of the stream 331 can be greater than the cross-machine direction width of the stream 319 and contribute superabsorbent material 317 to both the center region 371 and the side regions 373. Of course, in other embodiments, it can be reversed, where the cross-machine direction width of the stream 331 is less than the cross-machine direction width of the stream 319. Such embodiments can result in a structure 101 that looks substantially similar to Figure 10BThe illustrated structure, one of the streams 319, 331 can have a center (in the cross-machine direction 338) that is free of superabsorbent material 317. In such cases, one of the streams 319, 331 can include two separate, spaced apart sub-streams of superabsorbent material 317. In such embodiments, the absorbent material deposition station 302a or 302b that includes one of the streams 319, 331 can only contribute superabsorbent material 317 to the side zones 373, while the other absorbent material deposition station 302a or 302b provides superabsorbent material 317 to both the center zone 371 and the side zones 373. Of course, in different embodiments, it can be the case that either of the absorbent material deposition stations 302a, 302b only contribute superabsorbent material 317 to the side zones 373 of the absorbent structure 101. According to some embodiments, the adhesive applicators 307, 309, 333, and / or 335 of the absorbent material deposition stations 302a, 302b that include a stream 317 or 331 that is split into two separate, spaced apart sub-streams can be configured to spray adhesive into the region between the two sub-streams of stream 319 or 317, such that the adhesive 308, 310, 334, and / or 336 used in process 400 is generally present in both the center zone 371 and the side zones 373 of the absorbent structure 101. Of course, in other embodiments, the adhesive applicators 307, 309, 333, and / or 335 of the absorbent material deposition stations 302a, 302b that include a stream 317 or 331 that is split into two separate, spaced apart sub-streams can be configured to only spray adhesive in the region of the sub-streams of stream 317 or 331, such that the adhesive 308 and / or 310 or 334 and / or 336 can not be generally present in the center zone 371 of the absorbent structure 101. Further, it can be the case that the basis weights of the side zones 373 can not be equal to one another. However, in most embodiments, the basis weights of the side zones 373 differ from one another by no more than 50%.

[0166] Figure 11A is a perspective view of a computer-generated image 420 of the deposition mixture 320, which is based on micro-CT images taken from an exemplary deposition mixture 320 formed by process 300. More specifically, the image is used to illustrate Figures 11A-11CThe illustrated computer generated mixture 420 of mixture 320 formed by process 300, where the streams 319 and binders 308 and 310 are configured as listed for the first exemplary absorbent structure detailed below, and the resulting structure 320 has superabsorbent material 317 disposed in an amount of 400 gsm, and where the binders 308, 310, 334, and 336 are present at an add-on rate of 5%. The mixture 320 is stained with osmium tetroxide and then micro-CT scanned according to standard known staining and scanning techniques. As part of the micro-CT process, a portion of the stained deposition mixture 320 is selected for imaging that is selected from approximately the center of the mixture 320 (e.g., structure 101) in both the width and length directions. The portion has dimensions of approximately 3 cm by 1 cm and is cut into approximately one thousand two hundred fifty individual segments that extend in the transverse direction 392, each segment extending from an end edge 395a to an end edge 395b and including 1986 pixels in the longitudinal dimension (e.g., along the longitudinal direction 392). Each segment further includes 504 pixels in the vertical direction 394 between the first surface 391 and the second surface 393. An 8.0 micron voxel size is used. From the captured segments, a three-dimensional model is generated and depicted in Figure 11A .

[0167] When the binders 308, 310, 334, and / or 336 are mixed with the superabsorbent material 317, the binder filaments 316 sprayed by the applicators 307, 309, 311, and / or 313 cross and connect to form a three-dimensional network 380 having networked binder filaments 381 that extend substantially throughout the three-dimensional space formed by the image 420, as can be seen in Figure 11B and Figure 11A . As used herein, the networked binder filaments 381 can be considered to extend substantially throughout the entire three-dimensional space formed by the deposition mixture of the image 420, with the networked binder filaments 381 extending between and intermixed with a majority or a supermajority of the individual superabsorbent materials 317. This configuration is in contrast to a configuration where the binder filaments extend over pockets or groups of superabsorbent particles and do not extend into and between the individual superabsorbent materials 317 of the pockets or groups of superabsorbent particles. The superabsorbent materials 317 are also disposed throughout the three-dimensional network 380, shown as particles 318, and immobilized by contact with one or more of the networked binder filaments 381.

[0168] Processes 300 and 400 can operate to mix the adhesive 308, 310, 334, and / or 336 with the superabsorbent material 317 to an extent such that the web adhesive filaments 381 contact substantially all of the individual superabsorbent materials 317. The web adhesive filaments 381 can wrap a majority or a supermajority of the individual superabsorbent materials 317. As used herein, the web adhesive filaments 381 can be considered to wrap the individual superabsorbent particles 318 if the combined length of the individual web adhesive filaments 381 in contact with the individual superabsorbent particles 318 is equal to at least 40% of the maximum perimeter of the individual superabsorbent particles 318.

[0169] As Figure 11B and Figure 11C and Figure 11B shown, Figure 11A is Figure 11C a top plan view of a portion of the image 420 of the deposited mixture, the image 420 of the deposited mixture can generally have a first surface 391 and a second surface 393 disposed opposite the first surface 391, and end edges 395a, 395b and side edges 397a, 397b. Each of the first surface 391 and the second surface 393 generally extend in a transverse direction 390 and a longitudinal direction 392. At each of the first surface 391 and the second surface 393, the web network 380 can include web adhesive filaments 381 that extend substantially in the transverse direction 390 and the longitudinal direction 392. For example, the first web adhesive filaments 383 can be seen to extend substantially along the first surface 391 in the transverse direction 390 and the longitudinal direction 392. The second web adhesive filaments 385 (shown in Figure 11C ) can extend substantially in the transverse direction 390 and the longitudinal direction 392 along the second surface 393.

[0170] The web adhesive filaments 381 of the three-dimensional web network 380 can further include vertically extending filaments 387 that can extend in a vertical direction 394 in Figure 11C . Figure 11A represents Figure 11D a transversely extending slice of the image 420 of the deposited mixture having a length of 0.5 mm in the longitudinal direction 392, showing the interaction of the particles 318 and the adhesive filaments 381 in more detail. Figure 11C-11D is the same image as Figure 11C , with the particles 318 removed to show the adhesive filaments 381 and their arrangement in the vertical direction 394 in more detail.

[0171] At least some of these vertically extending filaments 387 extend all the way from the first surface 391 to the second surface 393 and connect the first web of adhesive filaments 383 to the second web of adhesive filaments 385 to form the three-dimensional web network 380. Of course, it can be seen that the vertically extending filaments 387 can not extend entirely in the vertical direction 394 and can twist and turn between and around the various superabsorbent particles 318 such that at least some of the vertically extending filaments 387 also extend in the lateral direction 390 and / or the longitudinal direction 392. In at least some embodiments, the various web adhesive filaments 381 can themselves extend along a portion of the first surface 391 (e.g., in the lateral direction 390 and / or the longitudinal direction 392), transition to extending in the vertical direction 394, and then connect with the second surface 392, possibly extending further along the longitudinal direction 392 and / or the lateral direction 390 at the second surface 392. This behavior can be seen with respect to the network adhesive filaments 389a and 389b.

[0172] In Figure 11D Another feature that can be seen to some extent in the structure 420 is the relative distribution of the network adhesive filaments 381 within the different vertical zones of the deposited mixture represented by the image 420. For example, as shown by the image 420, the image 420 can be divided into outer zones 396 and inner zones 398 disposed between the outer zones 396 that span the vertical direction 394. The outer zones 396 can each be defined by a thickness of 33% of the total thickness of the structure 420, while the inner zones 398 can be defined by a thickness of 33% of the total thickness of the structure 420. First Exemplary Absorbent Structure and Second Exemplary Absorbent Structure As shown by the image 420, the image 420 can be divided into outer zones 396 and inner zones 398 disposed between the outer zones 396 that span the vertical direction 394. The outer zones 396 can each be defined by a thickness of 33% of the total thickness of the structure 420, while the inner zones 398 can be defined by a thickness of 33% of the total thickness of the structure 420.

[0173] It has been found that, ideally, the processes 300 and / or 400 can penetrate the adhesive 308, 310, 334, and / or 336 into the inner zones 398, thereby facilitating high SAM capture values and greater pad uniformity through more uniform distribution of the superabsorbent material 317 and the adhesive 308, 310, 334, and / or 336 throughout the structure 420. This is especially true when the base weight of the superabsorbent material 317 of the formed mixture 320 of the present disclosure is greater than 300 gsm, or greater than 400 gsm, or greater than 500 gsm, or greater than 600 gsm, or greater than 700 gsm. As the desired base weight of the superabsorbent material 317 in the mixture 320 increases, it becomes more difficult for the adhesive 308, 310, 334, and / or 336 to penetrate into the interior of the flow 319 and / or 331, and the processes 300 and / or 400 are better in comparison to prior art processes.

[0174] To assess the ability of the processes 300 and / or 400 to penetrate the adhesive into the interior zone 398 of the formed mixture 320, an analysis of two sample codes was performed. In the analysis, two sample codes were produced in accordance with the process 400, which had a basis weight of superabsorbent material of 500 gsm and an adhesive disposed at an add-on level of 5%. From these two sample codes, micro-CT images were formed of portions of the codes in accordance with the standard procedures and techniques described above. Then, the adhesive distribution test method described in detail below was performed on the generated micro-CT images to determine the relative amount of adhesive located within the interior zone 398 of the imaged portions of the two sample codes. The micro-CT images were generated using the known staining and imaging methods described above.

[0175] In accordance with the adhesive distribution test method, the first sample code was found to have 28.0% of the total amount of adhesive within the first sample code located within the interior zone 398 of the first sample code, with a standard deviation of 8.4%. The second sample code was found to have 30.7% of the total amount of adhesive within the second sample code located within the interior zone 398 of the second sample code, with a standard deviation of 8.9%. Thus, the mixture 320 formed in accordance with the processes 300 and / or 400 can result in greater than 28% of the total amount of adhesive within the mixture 320 being located within the interior zone 398, or greater than 30.5% of the total amount of adhesive within the mixture 320 being located within the interior zone 398. However, in further potential embodiments, it is believed that through slight modifications to the processes 300 and / or 400, such as in the adhesive add-on level, vacuum energy, roll gap pressure, location and angle of the nozzle, etc., greater than 33% of the total amount of adhesive within the mixture 320 can be achieved to be located within the interior zone 398 of the mixture 320, or even greater than 35%. Such high penetration of adhesive within the interior zone 398 of the formed mixture of the processes 300 and / or 400 helps to drive improved SAM capture, wet mat integrity, and mat uniformity results, as described in greater detail below. The absorbent structures 101 produced by the processes 300 and / or 400 have shown to have beneficial properties over prior art absorbent structures. For example, the processes 300 and / or 400 have been shown to produce absorbent structures 101 that provide superior performance with respect to the capture and immobilization of superabsorbent material 317, superior mat integrity of the formed absorbent structure 101, and more uniform distribution of the superabsorbent material 317 throughout the formed absorbent structure 101 as compared to prior art structures, as will be described in greater detail below.

[0176] To compare the absorbent structures, a number of different absorbent structures 101 were formed by the processes 300 and / or 400 and tested against absorbent structures formed by prior art processes. As will be described below, the exemplary absorbent structures 101 and exemplary prior art absorbent structures were compared against the SAM capture test method, the wet pad integrity test method, and the pad uniformity test method, as described below, to produce comparison results.

[0177] Third Exemplary Absorbent Structure

[0178] As described herein, first exemplary absorbent structures 101 were formed according to the exemplary process 300, labeled as absorbent structures S23, S27, S53, and S57. Specifically, first exemplary absorbent structures 101 were formed according to the exemplary process 300 having a basis weight of 200 gsm and an adhesive add-on of 3% (labeled as structure S23), having a basis weight of 200 gsm and an adhesive add-on of 7% (labeled as structure S27), having a basis weight of 500 gsm and an adhesive add-on of 3% (labeled as structure S53), and having a basis weight of 500 gsm and an adhesive add-on of 7% (labeled as structure S57).

[0179] The settings for the process 300 used to form the exemplary absorbent structures S23, S27, S53, and S57 included the use of two adhesive applicators 307, 309, where the adhesive applicator 307 was positioned a distance from the web material 303 and the stream 319 such that the adhesive contacted the stream 319 at a distance of 6.4 mm (e.g., distance 361) from the web material 303. The adhesive applicator 309 was positioned a distance from the web material 303 and the stream 319 such that the adhesive 310 contacted the stream 319 at a distance of 16 mm (e.g., distance 367 plus distance 361) from the web material 303. In addition to this, the chute 315 was positioned at a distance 359 of 76 mm from the web material 303. The adhesive nozzle 321 was positioned at an angle 359a of 60 degrees relative to the machine direction 330, and the adhesive nozzle 323 was also positioned at an angle of 60 degrees relative to the machine direction 330. The nozzles 321 and 232 were Universal TM Signature TM nozzles available from Nordson Corporation. The chute width 356 was set to 12 mm, and the nip pressure at the nip station 327 was 1 PLI (175.1 N / m). An 8 gsm SMS material was used for the material web material 303 and 324. Vacuum energy was applied such that the forming surface had a pressure differential of approximately 0.51 m of water column.

[0180] Figure 3

[0181] Second example absorbent structures 101, labeled as absorbent structures D23-D67, were formed according to exemplary method 400 as described herein. Specifically, second example absorbent structures 101 were formed according to exemplary method 400 having a basis weight of 200 gsm and an adhesive add-on level of 3% (labeled as structure D23), having a basis weight of 200 gsm and an adhesive add-on level of 4% (labeled as structure D24), having a basis weight of 200 gsm and an adhesive add-on level of 5% (labeled as structure D25), having a basis weight of 200 gsm and an adhesive add-on level of 6% (labeled as structure D26), and having a basis weight of 200 gsm and an adhesive add-on level of 7% (labeled as structure D27). Further second example absorbent structures 101 were formed according to exemplary method 400 having a basis weight of 300 gsm and an adhesive add-on level of 3% (labeled as structure D33), having a basis weight of 300 gsm and an adhesive add-on level of 4% (labeled as structure D34), having a basis weight of 300 gsm and an adhesive add-on level of 5% (labeled as structure D35), having a basis weight of 300 gsm and an adhesive add-on level of 6% (labeled as structure D36), and having a basis weight of 300 gsm and an adhesive add-on level of 7% (labeled as structure D37). Still further second example absorbent structures 101 were formed according to exemplary method 400 having a basis weight of 400 gsm and an adhesive add-on level of 3% (labeled as structure D43), having a basis weight of 400 gsm and an adhesive add-on level of 4% (labeled as structure D44), having a basis weight of 400 gsm and an adhesive add-on level of 5% (labeled as structure D45), having a basis weight of 400 gsm and an adhesive add-on level of 6% (labeled as structure D46), and having a basis weight of 400 gsm and an adhesive add-on level of 7% (labeled as structure D47). Even still further second example absorbent structures 101 were formed according to exemplary method 400 having a basis weight of 500 gsm and an adhesive add-on level of 3% (labeled as structure D53), having a basis weight of 500 gsm and an adhesive add-on level of 4% (labeled as structure D54), having a basis weight of 500 gsm and an adhesive add-on level of 5% (labeled as structure D55), having a basis weight of 500 gsm and an adhesive add-on level of 6% (labeled as structure D56), and having a basis weight of 500 gsm and an adhesive add-on level of 7% (labeled as structure D57).A further second exemplary absorbent structure 101 is formed according to the exemplary method 400 having a basis weight of 600 gsm and an adhesive add-on of 2% (labeled Structure D62), having a basis weight of 600 gsm and an adhesive add-on of 3% (labeled Structure D63), having a basis weight of 600 gsm and an adhesive add-on of 4% (labeled Structure D64), having a basis weight of 600 gsm and an adhesive add-on of 5% (labeled Structure D65), having a basis weight of 600 gsm and an adhesive add-on of 6% (labeled Structure D66), and having a basis weight of 600 gsm and an adhesive add-on of 7% (labeled Structure D67).

[0182] The settings for the process 400 used to form the exemplary absorbent structures D23-D27, D33-D37, D43-D47, D53-D57, and D62-D67 include the use of two adhesive applicators 307, 309 within the absorbent material deposition station 302a. The adhesive applicator 307 is positioned a distance from the web 303 and the stream 319 such that the adhesive contacts the stream 319 at a distance of 6.4 mm (e.g., distance 361) from the web 303. The adhesive applicator 309 is positioned a distance from the web material 303 and the stream 319 such that the adhesive 310 contacts the stream 319 at a distance of 16 mm (e.g., distance 367 plus distance 361) from the web material 303. In addition to this, the chute 315 is positioned at a distance 359 of 76 mm from the web material 303. The adhesive nozzle 321 is positioned at an angle 359a of 60 degrees relative to the machine direction 330, and the adhesive nozzle 323 is also positioned at an angle of 60 degrees relative to the machine direction 330. The chute width 356 is set to 12 mm, and the nip pressure at the nip station 327 is 1 PLI (175.1 N / m). The settings for the absorbent material deposition station 302b are substantially the same as the settings for the absorbent material deposition station 302a described above. An 8 gsm SMS is used for the material web material 303 and 324, and vacuum energy is applied such that the forming surface has a pressure differential of approximately 0.51 m of water column.

[0183] Figure 3

[0184] As described herein, a third exemplary absorbent structure 101 (labeled as absorbent structure N23-N67 (or more specifically, absorbent structures N23-N27, N33-N37, N43-N47, N53-N57, and N62-N67)) was formed according to the exemplary prior art process of U.S. Patent No. 8,986,474 to Kufner et al., assigned to Nordson Corporation (hereinafter “Nordson,” or the “Nordson reference”). Exemplary absorbent structures N23-N67 were formed according to the Nordson process of U.S. Patent No. 8,986,474 SAM Capture Test Method Results where a single absorbent material deposition station having two adhesive dispensing units was used. Such dispensing units (e.g., units 22, 72 of the Nordson reference Wet Pad Integrity Test Method Results were configured such that the discharged adhesive streams 26, 76 converged at the powder mixture 56 and were each oriented at a 45 degree angle. The adhesive streams 26, 76 each contacted the powder mixture 56 12.7 millimeters from the facing web material. A chute similar to chute 315 was used and placed 76 mm from the facing web material and set to have a width of 12 mm (e.g., similar to the width 356 of the chute 315 of the present disclosure). Although not necessarily disclosed in the Nordson reference, the absorbent structures formed according to the Nordson process were subjected to the same post-processing as described for methods 300 and 400, namely passing through a nip station (such as nip station 327) at a setting of 1 PLI (175.1 N / m) and then cut into individual absorbent structures 101. Vacuum energy was applied such that the forming surface had a pressure differential of approximately 0.51 m of water column. As with the first and second exemplary absorbent structures, an 8 gsm SMS material was used for the material facing web materials 303 and 324.

[0185] A number of absorbent structures were produced using the prior art Nordson process set up as described above. Specifically, a third exemplary absorbent structure 101 was produced having a basis weight of 200 gsm and an adhesive add-on of 3% (labeled Structure N23), having a basis weight of 200 gsm and an adhesive add-on of 4% (labeled Structure N24), having a basis weight of 200 gsm and an adhesive add-on of 5% (labeled Structure N25), having a basis weight of 200 gsm and an adhesive add-on of 6% (labeled Structure N26), and having a basis weight of 200 gsm and an adhesive add-on of 7% (labeled Structure N27). Further third exemplary absorbent structures were formed according to the exemplary Nordson process having a basis weight of 300 gsm and an adhesive add-on of 3% (labeled Structure N33), having a basis weight of 300 gsm and an adhesive add-on of 4% (labeled Structure N34), having a basis weight of 300 gsm and an adhesive add-on of 5% (labeled Structure N35), having a basis weight of 300 gsm and an adhesive add-on of 6% (labeled Structure N36), and having a basis weight of 300 gsm and an adhesive add-on of 7% (labeled Structure N37). Still further third exemplary absorbent structures were formed according to the Nordson process having a basis weight of 400 gsm and an adhesive add-on of 3% (labeled Structure N43), having a basis weight of 400 gsm and an adhesive add-on of 4% (labeled Structure N44), having a basis weight of 400 gsm and an adhesive add-on of 5% (labeled Structure N45), having a basis weight of 400 gsm and an adhesive add-on of 6% (labeled Structure N46), and having a basis weight of 400 gsm and an adhesive add-on of 7% (labeled Structure N47). Even further third exemplary absorbent structures were formed according to the Nordson process having a basis weight of 500 gsm and an adhesive add-on of 3% (labeled Structure N53), having a basis weight of 500 gsm and an adhesive add-on of 4% (labeled Structure N54), having a basis weight of 500 gsm and an adhesive add-on of 5% (labeled Structure N55), having a basis weight of 500 gsm and an adhesive add-on of 6% (labeled Structure N56), and having a basis weight of 500 gsm and an adhesive add-on of 7% (labeled Structure N57).A further third exemplary absorbent structure 101 is formed having a basis weight of 600 gsm and an adhesive add-on of 2% (labeled Structure N62), having a basis weight of 600 gsm and an adhesive add-on of 3% (labeled Structure N63), having a basis weight of 600 gsm and an adhesive add-on of 4% (labeled Structure N64), having a basis weight of 600 gsm and an adhesive add-on of 5% (labeled Structure N65), having a basis weight of 600 gsm and an adhesive add-on of 6% (labeled Structure N66), and having a basis weight of 600 gsm and an adhesive add-on of 7% (labeled Structure N67).

[0186] Pad Uniformity Test Method Results

[0187] The following absorbent structures 101, absorbent structures D23-D27, D33-D37, D43-D47, D53-D57, and D62-D67, and absorbent structures N23-N27, N33-N37, N43-N47, N53-N57, and N62-N67, labeled as absorbent structures S23, S27, S53, and S57, were tested according to the SAM Capture Test Method described in greater detail below. Five samples were tested for each code, and the average results for each code are shown in Tables 1A-1L below.

[0188] The SAM gsm and %Adh columns represent the process settings used to form the corresponding structure. For example, the SAM gsm column indicates that the process was set to produce an absorbent structure 101 having an average basis weight of 200 gsm of superabsorbent particles 17. The %Adh column indicates that the process was set to produce an absorbent structure 101 having a specified weight percentage of the combined average basis weight of the one or more adhesives used of the weight of the superabsorbent particles 17 of the structure 101. As one specific example, when the SAM gsm column indicates 200 gsm and the %Adh column indicates 3%, the specified absorbent structure 101 is formed to have a basis weight of adhesive that is 3% of the 200 gsm of superabsorbent particles 17 disposed throughout the structure 101, i.e., 6 gsm. The average %SAM Capture value is a measure of the percentage of superabsorbent material 317 retained by the particular absorbent structure 101 at the end of the SAM Capture Test Method.

[0189]

[0190] Table 1A

[0191]

[0192] Table 1B

[0193]

[0194] Table 1C

[0195]

[0196] Table 1D

[0197]

[0198] Table 1E

[0199]

[0200] Table 1F

[0201]

[0202] Table 1G

[0203]

[0204]

[0205] Table 1H

[0206]

[0207] Table 1I

[0208]

[0209] Table 1J

[0210]

[0211] Table 1K

[0212]

[0213] Table 1L

[0214] Accordingly, there is a clear difference in performance between some of the codes formed according to aspects of the present disclosure and codes produced by the Nordson process, particularly codes having a relatively lower %Adh value. Specifically, it can be seen that the absorbent structures 101 having a basis weight of between 400 gsm and 600 gsm and a %Adh value of between 4% and 5% of the superabsorbent particles 17 produced according to aspects of the present disclosure have a %SAM capture value of greater than 98.0, which is higher than any of the absorbent structures produced by the Nordson process (Code N45, falling within the specified ranges of SAM gsm and %Adh, having the highest %SAM capture value of 97.9). As an alternative, the structures 101 having a basis weight of between 400 gsm and 600 gsm and a %Adh value of between 4% and 5% of the superabsorbent particles 17 formed according to aspects of the present disclosure can be described as having a %SAM capture value of greater than 98.5.

[0215] Further, many of the codes produced according to aspects of the present disclosure have a % SAM Acquisition value greater than 98.0, such as Code D65 (% SAM Acquisition value of 98.1), D64 (% SAM Acquisition value of 98.3), D55 (% SAM Acquisition value of 99.5), D54 (% SAM Acquisition value of 99.3), D45 (% SAM Acquisition value of 99.8), and D44 (% SAM Acquisition value of 99.3). Many of the corresponding codes for absorbent structures produced according to the Nordson process (e.g., codes with corresponding SAM gsm and % Adh values) have much lower % SAM Acquisition values, for example, Code N65 has a % SAM Acquisition value of 87.0, Code N64 has a % SAM Acquisition value of 88.8, and Code N44 has a % SAM Acquisition value of 97.3.

[0216] Further emphasizing codes with a basis weight between 500 gsm and 600 gsm and a % Adh value between 4% and 5%, absorbent structures 101 formed according to aspects of the present disclosure all have a % SAM Acquisition value greater than 96.5. For example, Codes D54, D55, D64, and D65 have % SAM Acquisition values of 99.3, 99.5, 98.3, and 98.1, respectively. The corresponding Codes N54, N55, N64, and N65 have % SAM Acquisition values of 94.8, 96.2, 88.8, and 87.0, respectively.

[0217] In cases where the basis weight of the superabsorbent particles 17 is between 500 gsm and 600 gsm and the % Adh value is between 3% and 4%, the codes for structures 101 formed according to aspects of the present disclosure can also have a performance advantage over codes for absorbent structures produced by the Nordson process. In such instances, structures 101 produced according to aspects of the present disclosure all have a % SAM Acquisition value greater than 95.0, which is higher than any code for absorbent structures produced by the Nordson process (Code N54, falling within the specified ranges for SAM gsm and % Adh, has the highest % SAM Acquisition value of 94.8).

[0218] Further, many of the codes produced according to aspects of the present disclosure have a % SAM Acquisition value greater than 95.0, such as Code D53 (% SAM Acquisition value of 97.2), D54 (% SAM Acquisition value of 99.3), D63 (% SAM Acquisition value of 95.6), and D64 (% SAM Acquisition value of 98.3). Many of the corresponding codes for absorbent structures produced according to the Nordson process have much lower % SAM Acquisition values, for example, Code N53 has a % SAM Acquisition value of 92.8, Code N63 has a % SAM Acquisition value of 88.1, and Code N64 has a % SAM Acquisition value of 88.8.

[0219] The structures 101 produced in accordance with aspects of the present disclosure with basis weights between 500 gsm and 600 gsm of superabsorbent particles 17 still outperformed the absorbent structures produced by the Nordson process where the %Adh value increased between 4% and 5%, as all of the structures had a %SAM capture value greater than 97.0. For example, the %SAM capture values for codes D54, D55, D64, and D65 were 99.3, 99.5, 98.3, and 98.1, respectively. The corresponding absorbent structures produced by the Nordson process (codes N54, N55, N64, and N65) had %SAM capture values of 94.8, 96.2, 88.8, and 87.0, respectively.

[0220] The structures 101 produced in accordance with aspects of the present disclosure with basis weights between 500 gsm and 600 gsm of superabsorbent particles 17 still outperformed the absorbent structures produced by the Nordson process where the %Adh value increased between 5% and 6%, as all of the structures had a %SAM capture value greater than 97.0. For example, the %SAM capture values for codes D55, D56, D65, and D66 were 99.5, 99.8, 98.1, and 98.9, respectively. The corresponding absorbent structures produced by the Nordson process (codes N55, N56, N65, and N66) had %SAM capture values of 96.2, 96.7, 87.0, and 85.6, respectively.

[0221] SAM Capture Test Method

[0222] In comparative measurements of absorbent structures 101 formed in accordance with aspects of the present disclosure and absorbent structures formed in accordance with the Nordson process, a number of different codes were produced. As shown in Table 2A below, absorbent structures 101 formed in accordance with aspects of the present disclosure were produced, labeled as codes DD23, DD27, DD53, and DD57. Codes DD23, DD27, DD53, and DD57 were formed by processes similar to those described above with respect to the second exemplary absorbent structure. In addition thereto, corresponding absorbent structures were formed in accordance with the Nordson process, as shown in Table 2B and labeled as NN23, NN27, NN53, and NN57. Codes NN23, NN27, NN53, and NN57 were formed by processes similar to those described above with respect to the third exemplary absorbent structure. Five of each of these codes were tested in accordance with the Wet Pad Integrity Test Method described in greater detail below, and the results are shown in Tables 2A and 2B below. The Avg # column details the average number of shakes imparted to the structure during the Wet Pad Integrity Test Method in which the structure maintained its integrity, with an upper limit of 50 shakes.

[0223]

[0224] Table 2A

[0225]

[0226] Table 2B

[0227] As can be seen from Tables 2A and 2B, the absorbent structures 101 formed in accordance with aspects of the present disclosure have a distinct benefit in terms of wet mat integrity as compared to absorbent structures formed in accordance with the Nordson process. For example, Code DD57 (representing an absorbent structure 101 formed to have an average basis weight of 500 gsm of superabsorbent material 317 and a combined basis weight of one or more adhesives that is 7% of the basis weight of the superabsorbent material 317) has a wet mat integrity value of 38, which is 110% higher than the wet mat integrity value of the corresponding Code NN57 formed in accordance with the Nordson process (the wet mat integrity value of NN57 is 18). In other embodiments, the absorbent structures 101 formed in accordance with aspects of the present disclosure can be described as having a wet mat integrity value of at least 25, or at least 30, or at least 35 when formed to have an average basis weight of 500 gsm of superabsorbent material 317 and a combined basis weight of one or more adhesives that is 7% of the basis weight of the superabsorbent material 317. As another example, Code DD53 (representing an absorbent structure 101 formed to have an average basis weight of 500 gsm of superabsorbent material 317 and a combined basis weight of one or more adhesives that is 3% of the basis weight of the superabsorbent material 317) has a wet mat integrity value of 3, which is higher than the wet mat integrity value of the corresponding Code NN53 formed in accordance with the Nordson process (the wet mat integrity of NN53 is 0), which process could not even withstand a single shake from the wet mat integrity test method.

[0228] In this manner, it can be seen that the absorbent structures 101 produced by processes 300 and 400 have better wet mat integrity than absorbent structures produced by prior art processes. For example, the processes disclosed herein include gravity feeding superabsorbent material 317 to a web material 303, forming a stream of superabsorbent material, and further including spraying a first side and a second side of the stream with adhesive. As described herein, the adhesive is mixed with the superabsorbent material 317 prior to deposition onto the web material 303. Thus, based on the results described above, these processes are additionally capable of producing absorbent structures 101 having a wet mat integrity value greater than or equal to 20, at least when used to produce structures 101 having superabsorbent material 317 disposed in an amount equal to 500 gsm and adhesive disposed in an amount equal to 7 wt% of the weight of the superabsorbent material 317. Of course, as described in more detail with respect to process 400, it can be the case that the process includes feeding two separate streams of superabsorbent material 317 toward the web material 303 and spraying adhesive on a first side and a second side of the two streams of superabsorbent material 317. Further, when such absorbent structures 101 are formed to have an average basis weight of superabsorbent material 317 of 500 gsm and a combined basis weight of the one or more adhesives that is 7% of the basis weight of the superabsorbent material 317, such processes according to the present disclosure can be described as capable of forming absorbent structures 101 having a wet mat integrity value of at least 25, or at least 30, or at least 35. In addition to this, when such absorbent structures 101 are formed to have an average basis weight of superabsorbent material 317 of 500 gsm and a combined basis weight of the one or more adhesives that is 3% of the basis weight of the superabsorbent material 317, such processes according to the present disclosure are capable of forming absorbent structures 101 having a wet mat integrity value of at least 1, or at least 2, or at least 3

[0229] Wet Pad Integrity Test Method

[0230] Another feature of the methods described herein, as compared to the Nordson process, is that the processes described herein are capable of producing absorbent structures 101 having a more uniform distribution of superabsorbent material 317 and adhesive fibers 316 throughout the formed structure 101 as compared to absorbent structures formed according to the Nordson process. This higher uniformity can allow the absorbent structures 101 to be thinner, more flexible, and better at handling fluids as compared to absorbent structures having similar basis weights of superabsorbent material and adhesive.

[0231] To compare the distribution of superabsorbent material 317 and binder fibers 316, a number of different absorbent structures 101 were formed in accordance with aspects of the present disclosure and compared to a number of different absorbent structures formed in accordance with the Nordson process. As can be seen from Tables 3A-3E, the absorbent structures 101 formed in accordance with aspects of the present disclosure are labeled with codes DDD23, DDD24, DDD27, DDD33, DDD34, DDD44, DDD45, DDD56, DDD62, DDD66, and DDD67. These codes were formed by a process similar to the process described above with respect to the second exemplary absorbent structure. The absorbent structures formed in accordance with the Nordson process are labeled with codes NNN23, NNN24, NNN27, NNN33, NNN34, NNN44, NNN45, NNN56, NNN62, NNN66, and NNN67. These codes were formed by a process similar to the process described above with respect to the third exemplary absorbent structure.

[0232] Tables 3A-3E report the results for the various codes in accordance with the Pad Uniformity Test Method, representing the results for a single sample for each code. The CD GL Var. column details the variation in gray level across a portion of the sample extending in the cross direction as determined in accordance with the Pad Uniformity Test Method. A lower gray level variance value indicates a generally more uniform structure, as the determined variance in gray level is lower. The CD Mean GL column reports the average gray level value for the sample as determined in accordance with the Pad Uniformity Test Method, while the GL % COV value reports the calculated gray level variability normalized with respect to the average gray level value. For example, for a given sample, the GL % COV value is determined by dividing the gray level standard deviation by the average gray level, and multiplying such calculated value by 100%. The determination of all of these values is described in greater detail below with respect to the Pad Uniformity Test Method.

[0233]

[0234] Table 3A

[0235]

[0236] Table 3B

[0237]

[0238] Table 3C

[0239]

[0240] Table 3D

[0241]

[0242] Table 3E

[0243] As can be seen from Tables 3A-3E, the structures 101 produced by the processes described herein produce much lower CD GL Var. values than the absorbent structures formed according to the Nordson process. For example, codes DDD23 and DDD24 have CD GL Var. values of less than 815, less than 800, less than 750, or less than 700, as determined according to the Pad Uniformity Test Method. Such CD GL Var. values are all less than the CD GL Var. values for the corresponding NNN23 code and NNN24 code. In other words, absorbent structures 101 formed according to aspects of the present disclosure, which have superabsorbent material 317 disposed at a basis weight of 200 gsm and one or more adhesives disposed at a combined basis weight of less than 4 wt% of the basis weight of the superabsorbent material 317, can have CD GL Var. values of less than 815, less than 800, less than 750, or less than 700, as determined according to the Pad Uniformity Test Method. In some of these embodiments, the one or more adhesives can be disposed at a combined basis weight of from 3 wt% to 4 wt% of the basis weight of the superabsorbent material 317.

[0244] Further examples show that codes DDD33 and DDD34 have CD GL Var. values of less than 675, less than 650, or less than 625, as determined according to the Pad Uniformity Test Method. Such CD GL Var. values are all less than the CD GL Var. values for the corresponding NNN33 code and NNN34 code. In other words, absorbent structures 101 formed according to aspects of the present disclosure, which have superabsorbent material 317 disposed at a basis weight of 300 gsm and one or more adhesives disposed at a combined basis weight of less than 4 wt% of the basis weight of the superabsorbent material 317, can have CD GL Var. values of less than 675, less than 650, or less than 625, as determined according to the Pad Uniformity Test Method. In some of these embodiments, the one or more adhesives can be disposed at a combined basis weight of from 3 wt% to 4 wt% of the basis weight of the superabsorbent material 317.

[0245] Still further examples show that the codes DDD44 and DDD45 have a CD GL Var. value of less than 575, less than 550, less than 525, or less than 500, as determined according to the Pad Uniformity Test Method. Such CD GL Var. values are all less than the CD GL Var. values of the corresponding NNN44 code and NNN45 code. In other words, absorbent structures 101 formed according to aspects of the present disclosure having superabsorbent material 317 disposed at a basis weight of 400 gsm and one or more adhesives disposed at a combined basis weight of less than 5 wt% of the basis weight of the superabsorbent material 317 can have a CD GL Var. value of less than 585, less than 550, less than 525, or less than 500, as determined according to the Pad Uniformity Test Method. In some of these embodiments, the one or more adhesives can be disposed at a combined basis weight of from 4 wt% to 5 wt% of the basis weight of the superabsorbent material 317.

[0246] Still further examples show that the codes DDD56 have a CD GL Var. value of less than 500, less than 475, less than 450, or less than 425, as determined according to the Pad Uniformity Test Method. Such CD GL Var. values are all less than the CD GL Var. value of the corresponding NNN56 code. In other words, absorbent structures 101 formed according to aspects of the present disclosure having superabsorbent material 317 disposed at a basis weight of 500 gsm and one or more adhesives disposed at a combined basis weight of 6 wt% of the basis weight of the superabsorbent material 317 can have a CD GL Var. value of less than 500, less than 475, less than 450, or less than 425, as determined according to the Pad Uniformity Test Method.

[0247] Table 3E highlights that absorbent structures 101 formed according to aspects of the present disclosure outperform absorbent structures formed according to the Nordson process, particularly at high basis weights of superabsorbent material 317. Codes DDD62, DDD63, and DDD67 have CD GL Var. values of less than 475, less than 450, less than 425, less than 400, or less than 375, as determined according to the Pad Uniformity Test Method. In particular, codes DDD66 and DDD67 have CD GL Var. values of less than 350, less than 325, or less than 300. Such CD GL Var. values are all less than the CD GL Var. values of the corresponding NNN62 code, NNN66 code, and NNN67 code. In other words, absorbent structures 101 formed according to aspects of the present disclosure, which have superabsorbent material 317 disposed at a basis weight of 600 gsm and one or more adhesives disposed at a combined basis weight of less than 7 wt% of the basis weight of the superabsorbent material 317, can have CD GL Var. values of less than 475, less than 450, less than 425, less than 400, or less than 375, as determined according to the Pad Uniformity Test Method. In some of these embodiments, the one or more adhesives can be disposed at a combined basis weight of from 2 wt% to 7 wt% of the basis weight of the superabsorbent material 317. In further examples of these examples, such absorbent structures 101 can have CD GL Var. values of less than 350, less than 325, or less than 300, where the basis weight of the one or more adhesives is disposed between 6 wt% and 7 wt% of the basis weight of the superabsorbent material 317.

[0248] Additional features of absorbent structures 101 formed in accordance with aspects of the present disclosure can include the following: Absorbent structures 101 having a basis weight of superabsorbent material 317 between 500 gsm and 600 gsm can have a CD GL Var. value of less than 475, less than 450, or less than 425. In at least some of these embodiments, the one or more adhesives present in such structures 101 can have a combined basis weight of less than 7%, or less than 6%, or between 6% and 7%, or between 2% and 7%. Absorbent structures 101 having a basis weight of superabsorbent material 317 between 400 gsm and 500 gsm can have a CD GL Var. value of less than 510, less than 500, less than 490, or less than 480. In at least some of these embodiments, the one or more adhesives present in such structures 101 can have a combined basis weight of less than 6%, or less than 5%, or between 4% and 6%. Absorbent structures 101 having a basis weight of superabsorbent material 317 between 300 gsm and 400 gsm can have a CD GL Var. value of less than 590, or less than 580. In at least some of these embodiments, the one or more adhesives present in such structures 101 can have a combined basis weight of less than 5%, or less than 4%, or between 3% and 5%. Absorbent structures 101 having a basis weight of superabsorbent material 317 between 200 gsm and 300 gsm and wherein the one or more adhesives present in such structures 101 have a combined basis weight between 3% and 4% can have a CD GL Var. value of less than 675, less than 665, or less than 655.

[0249] When using the GL%COV values, it can be seen that the absorbent structures 101 formed according to aspects of the present disclosure generally have lower variation across determined gray levels of different basis weights. For example, codes DDD44, DDD45, DDD56, DDD62, DDD66, and DDD67 all have GL%COV values of less than 34.5, less than 34, or less than 33.5. Such GL%COV values are all less than the GL%COV values for the corresponding NNN44 code, NNN45 code, NNN56 code, NNN62 code, NNN66 code, and NNN67 code. In other words, absorbent structures 101 formed according to aspects of the present disclosure, which have superabsorbent material 317 disposed at a basis weight between 400 gsm and 600 gsm and one or more adhesives disposed at a combined basis weight of less than 7 wt% of the basis weight of the superabsorbent material 317, can have GL%COV values of less than 34.5, less than 34, or less than 33.5, as determined according to the Pad Uniformity Test Method. In some of these embodiments, the one or more adhesives can be disposed at a combined basis weight of between 4% and 7%, or between 4% and 6%, of the basis weight of the superabsorbent material 317. In further embodiments of any of these embodiments, the superabsorbent material 317 can be disposed at a basis weight between 400 gsm and 500 gsm.

[0250] As another example, codes DDD34, DDD44, and DDD45 all have GL%COV values of less than 31.5 or less than 31.3. The lowest GL%COV value for the corresponding NNN34 code, NNN44 code, and NNN45 code is 31.6. In other words, absorbent structures 101 formed according to aspects of the present disclosure, which have superabsorbent material 317 disposed at a basis weight between 300 gsm and 400 gsm and one or more adhesives disposed at a combined basis weight between 4 wt% and 5 wt% of the basis weight of the superabsorbent particles 318, can have GL%COV values of less than 31.5, or less than 31.3, as determined according to the Pad Uniformity Test Method.

[0251] Pad Uniformity Test Method

[0252] The individual sample absorbent structures are first obtained, whether by deconstructing a commercially available product or by obtaining the individual structures directly from the production line prior to incorporation into a product. If obtained from a commercially available product, the typical product deconstruction methods should be used to only obtain the absorbent structure, such as using: a freeze spray or other equivalent product that helps to deactivate any adhesive that is layering the various layers of the product together, thereby allowing the layers to be more easily separated; and / or scissors to cut one or more portions of the product. If obtained directly from the production line, the sample absorbent structures should be at least solidified for 24 hours.

[0253] Once the sample absorbent structure is ready, each individual sample should be weighed and the weight recorded. Next, each sample structure is preferably peeled off over a trash can or similar to capture any shed material. The sample can be peeled by grasping one outer web material in each hand at one end of the structure and pulling apart in a peeling motion. Once pulled apart, the separated web is lightly shaken over the trash can and then placed back on the scale for a second weighing and recorded.

[0254] The difference between the first recorded weight of the sample and the second recorded weight of the sample represents the amount of superabsorbent material lost. This difference can then be used to determine the percentage of the total amount of superabsorbent material retained. In the present disclosure, since the web material, basis weight of the deposited superabsorbent material, and amount of adhesive added are the same for the sample structures being compared, the difference is simply divided by the first recorded weight of the sample to arrive at the reported percentage of superabsorbent material retention value. However, when comparing different samples, the basis weight and size of the web material can be considered, for example, by subtracting the total weight of the sample web material from the first and second recorded weights. The total weight of the adhesive is generally negligible for the determination of the retention value percentage and is therefore not considered separately.

[0255] Adhesive Distribution Test Method

[0256] Individual sample absorbent structures are first obtained, either by deconstructing a commercially available product or by obtaining the individual structures directly from the production line prior to incorporation into a product. If obtained from a commercially available product, a typical product deconstruction method should be used to only obtain the absorbent structure, such as using: a freeze spray or other equivalent product that helps to deactivate any adhesive that lamination the layers of the product together, thereby allowing the layers to be more easily separated; and / or scissors to cut one or more portions of the product open. If obtained directly from the production line, the sample absorbent structures should be at least 24 hours cured.

[0257] Once obtained, the target location of each sample is marked. The target location is marked 8.5 cm from the front edge of the sample. If the sample is removed from a product, the front edge of the sample is the edge closest to the front of the product; if the sample is obtained directly from the production line, the front edge of the sample is the edge facing the closest to the front of the product. The product should then be adhered to a light box or other suitable work surface. The sample can be adhered with double-sided tape or the like positioned at the front edge and / or back edge of the sample.

[0258] Next, a plastic tube having a length of 152 mm and a diameter of 51 mm (3.5 mm wall thickness, 44 mm inner diameter) is placed in the center of the target location. A plastic funnel is placed on top of the plastic tube and 100 ml of 0.9% blue saline is poured into the funnel. Care should be taken not to apply any pressure to the sample surface while securing the tube in place. In addition to this, the funnel spout should be tilted towards the tube wall so that the saline flows down the tube wall before it touches the sample surface. After pouring the liquid into the funnel, a 5 minute timer is set.

[0259] After 5 minutes, the sample is hung on a product shaker. The product shaker consists of a simple frame with a linear actuator attached to the top of the frame and oriented in the vertical direction. A 12 inch (305 mm) long horizontal bar is directly connected to the actuator and two product clips are attached to the horizontal bar. The sample absorbent structure leading edge is connected to the product shaker through the clips. The product shaker is then turned on and the number of shakes is counted. The linear actuator is configured to move the 12 inch bar up and down a total linear distance of 1 inch (25.4 mm) per half stroke (one move down or one move up). A full stroke move counts as one shake. Many commercially available linear actuators can be used as part of this product shaker. For example, a commercially available 12V or 24V actuator with a 25 mm stroke and a rating of approximately 50 pounds and an actuation of approximately 30 mm per second can be a particularly suitable actuator. Any suitable simple drive circuit can be utilized to operate the linear actuator through extension and retraction cycles. While the product shaker is on, the sample is observed for any partial breaks, which constitute any cracks or gaps that appear in the sample. Once a first partial break is observed, the number of shakes is recorded and the product shaker is turned off. If no partial cracks are observed after 50 shakes, the test is stopped and the sample is recorded as having a value of 50 shakes.

[0260] Embodiments

[0261] The image analysis methods described herein can be used to determine cross-machine direction (CD) gray scale variability properties of thin, fluffless absorbent webs, including structures 101 formed according to methods 300 and 400 of the present disclosure and including structures formed according to the Nordson process. In this case, the CD gray scale variability of the thin, fluffless absorbent web provides an indication of the uniformity of distribution of adhesive and superabsorbent particles throughout the web. For example, a web having a lower CD gray scale variation can be considered to have adhesive and superabsorbent particles arranged relatively more uniformly across the web, as the amount of light passing through the web is relatively more uniform throughout the web as compared to a web having a relatively higher CD gray scale variation, as will be explained in more detail below.

[0262] The method for determining CD gray scale variation includes the use of diffuse transmitted light that is passed through the web and detected by a camera. Specifically, the camera can be a CCD camera such as the Leica Microsystems DFC 310 camera available from Leica Microsystems, Heerbrugg, Switzerland. The camera can be mounted to a large viewfinder camera stand such as the Pentax MP4 large viewfinder camera stand or equivalent. An adjustable lens assembly such as a Nikon 35-mm lens with aperture set to 4 is connected to the camera through a C-adapter. The camera is set to monochrome mode and a flat field correction is performed on a white background prior to analysis.

[0263] An automated stage including a transparent support is placed on the upper surface of the large viewfinder between the video camera and the diffuse light source of the large viewfinder. The automated stage can be a model HM-1212 from Design Components, Inc. or equivalent. Diffuse transmitted illumination can be provided by four LED tubes (EMC-9 watt, dimmable) set below the automated stage and the large viewfinder includes a diffuser plate between the LED tubes and the automated stage. The illumination level of the LED tubes can be controlled via a common voltage controller equipped with knobs or sliders for adjustment.

[0264] Two black masks are placed on the transparent support of the automated stage, spaced three inches apart, and having a long dimension that extends to the front and back of the automated stage (e.g., toward and away from the camera stand of the large viewfinder). The web sample is laid flat on the transparent support and centered between the black masks so that only the central region of the sample is illuminated. The web sample is oriented similar to the black masks with the longitudinally extending side edges (e.g., long dimension side edges) of the web sample facing toward and away from the camera stand. The camera and lens assembly are mounted to the large viewfinder camera stand at a distance above the sample that provides an image field size of approximately 4 and a half inches across the width of the automated stage (e.g., perpendicular to the longitudinally extending side edges of the sample).

[0265] Analysis is performed by placing the web sample on the automated stage as described above under the optical axis of the camera and lens assembly. The sample must be laid flat and care is taken to ensure that wrinkles or similar distortions are eliminated or avoided. An image analysis software package is used to monitor and adjust the illumination level, acquire images, and then perform measurements to determine the gray scale variation. For the described analysis, the LAS software platform from Leica Microsystems, Inc. and a custom written algorithm CD Variation Gray Scale Algorithm (ActivTech)-1 are used to monitor and adjust the illumination level for each sample and perform the gray scale variation measurements. The algorithm, which is run using the LAS macro editor platform, is shown below.

[0266] NAME = Variation Gray Scale (Activ Tech)-1

[0267] Purpose = Measure the gray scale values of the grid elements on the CD

[0268] Conditions = DFC 310 camera; 35 mm adjustable lens (f / 4); diffuse transmitted light; bar = 76 cm

[0269] Author = D. G. Biggerstaff

[0270] Date = February 21, 2020

[0271] Open data file and set variables

[0272] PauseText ("Now enter the EXCEL data file and image file prefix name.") Input (Title$)

[0273] OPENFILE$ = "C:\Data\102888-Graverson\" + Title$ + ".xls"

[0274] Open file (OPENFILE$, channel #CHAN)

[0275] Set graph variables

[0276] GRAPHNX = 6

[0277] GRAPHNY = 2

[0278] GRAPHWID = 790

[0279] GRAPHHGHT = 118

[0280] GRAPHORGX = 270

[0281] GRAPHORGY = 100

[0282] GRAPHTHIK = 2

[0283] GRAPHORNT = 0

[0284] GRAPHOUT = 0

[0285] Count = 0

[0286] Set and calibrate

[0287] Calculated value = 0.0833 mm / px

[0288] Calculated value = 0.0833

[0289] Calibrate (local)

[0290] Input result header

[0291] File Result Header (Channel #1)

[0292] File Line (Channel #1)

[0293] File Line (Channel #1)

[0294] Image Box (x 0, y 0, width 1392, height 1040)

[0295] Measurement Frame (x 260, y 72, width 806, height 962)

[0296] Sample Loop

[0297] For (Sample = 1 to 3, Step 1)

[0298] PauseText ("Place sample on stage.")

[0299] Image Set DC Twain [Pause] (Camera 1, Auto Exposure Off, Gain 0.00, Exposure Time 15.69 ms, Brightness 0, Lamp 49.99)

[0300] Phase (Define Origin)

[0301] Phase (Scan Pattern, 1 x 3 Fields, Size 102000.000000 x 96570.000000)

[0302] Image Loop

[0303] For (Image = 1 to 3, Step 1)

[0304] Get Image

[0305] Image Set DC Twain [Pause] (Camera 1, Auto Exposure Off, Gain 0.00, Exposure Time 15.69 ms, Brightness 0, Lamp 49.99)

[0306] Color Transform (Monochrome Mode)

[0307] Get (Go To Image 0)

[0308] Count = Count + 1

[0309] -- The next line is the image storage location on the hard drive.

[0310] ACQFILE$ = "C:\Images\102888-Graverson\" + TITLE$ + "_" + STR$(COUNT) + ".tif"

[0311] Write Image (From ACQOUTPUT to file ACQFILE$)

[0312] GRAPHORGY = 100

[0313] Analysis cycle

[0314] For (analysis = 1 to 4, step 1)

[0315] Binary processing

[0316] Graph (inverted grid, GRAPHNX x GRAPHNY lines, grid size GRAPHWID x

[0317] GRAPHHGHT, origin GRAPHORGX x GRAPHORGY,

[0318] Thickness GRAPHTHIK, orientation GRAPHORNT, to GRAPHOUT clear)

[0319] Display (image 0 (on), frame (on, on), plane (0, off, off, off, off, off), lut0, x 0, y 0, z 0,

[0320] Reduce off)

[0321] Measure feature gray level

[0322] Measure feature (plane binary 0, 32 feret, minimum area: 4, gray image: image 0)

[0323] Selected parameters: X FCP, Y FCP, MeanGrey, GreyVarianc

[0324] File feature result (channel #1)

[0325] File line (channel #1)

[0326] File line (channel #1)

[0327] File line (channel #1)

[0328] Measure GL%COV

[0329] MGREYIMAGE = 0

[0330] MGREYMASK = 0

[0331] Measure gray (plane MGREYIMAGE, mask MGREYMASK,

[0332] Histogram to GREYHIST (256), statistics to GREYSTATS (2))

[0333] Selected parameters: MeanGrey, standard deviation

[0334] MEANGREY = GREY STATS (1)

[0335] GREYSDEV = GREY STATS (2)

[0336] glpercov = greys dev / mean grey*100

[0337] File ("GL %COV = ", channel #1)

[0338] File (GLPERCCOV, channel #1, 2 digits after '.')

[0339] File line (channel #1)

[0340] File line (channel #1)

[0341] GRAPHORGY = GRAPHORGY + 250

[0342] Next (analysis)

[0343] Phase (step, wait until stop + 550 ms)

[0344] Next (image)

[0345] Next (sample)

[0346] Close file (channel #1)

[0347] End

[0348] After the algorithm is executed using the Leica software, the system will prompt the analyst to enter the EXCEL data file sample and image file prefix name that will be used to store the measurement data and acquired image files. Both will be saved on the computer hard drive. Next, the system will prompt the analyst to properly place the sample on the sample holder so that the area to be measured is between the two black masks. The top edge of the sample should also be at least one inch above the top edge of the field image or higher. After the sample is properly placed, the analyst continues with the algorithm and the system will then prompt the analyst to adjust the illumination level so that the white level displayed is set to approximately 0.95. Once set, the software algorithm then proceeds automatically to acquire and save the image and then performs the image processing and analysis steps by placing a five grid pattern across the sample width (e.g., on a CD) and taking the average gray scale and gray scale variation measurements within each individual grid. This data is then exported to the previously named EXCEL spreadsheet and the same grid is used to measure the average and standard deviation of the gray scale level under the entire grid at the same time. The algorithm then calculates the corresponding gray scale percent coefficient of variation (GL%COV) from this data and exports this data to the EXCEL spreadsheet. The GL%COV is calculated as follows:

[0349] GL%COV = Gray Scale Standard Deviation / Average Gray Scale x 100% (1)

[0350] The measurement grid across the CD is approximately 66 mm wide and is subdivided into five equal sized grids. The average gray scale and gray scale variation measurements are taken for each grid and the GL%COV measurement is taken for all the combined grids. After the first measurement is taken near the top of the image, the algorithm moves the grid down 2.1 cm and then takes a second measurement on the same image and exports it to the EXCEL spreadsheet. This is repeated two more times so that a total of four CD run areas are measured for each image. The algorithm then instructs the automated stage to move the sample longitudinally 8.2 cm and then begins the process of setting the white level again for the next image. For each sample replicate, three separate images are acquired and analyzed. A total of three sample replicates are then analyzed for each sample.

[0351] For the gray scale variation measurements, the five measurements taken for each grid location are then averaged in the EXCEL spreadsheet. These averages are then accumulated over the 36 different grid locations (i.e., 3 replicates x 3 images x 4 CD locations = 36 CD locations) to compare different samples. After the results are obtained from the different samples, they can be compared to each other by performing basic statistical analysis such as a Student's T analysis at a 90% confidence level.

[0352] ​

[0353] The sample to be imaged is first stained with an osmium tetroxide fume to cause the adhesive to selectively absorb a sufficient amount of osmium to make it more easily contrasted with the highly absorbent and polymeric fibers during micro-CT imaging. The sample is placed in an enclosed, air-tight chamber, a small vial of osmium tetroxide is added, and the sample is stained. The chamber is then immediately sealed and allowed to interact with the osmium tetroxide for at least 24 hours. Because osmium tetroxide is highly toxic, the staining process is performed in a fume hood. After 24 hours, the adhesive should appear black in color. After re-opening the chamber, it is allowed to vent in the fume hood for an additional 24 hours to ensure that any unreacted osmium tetroxide is allowed to escape harmlessly. After the second 24 hour period, the sample is now ready for imaging in the micro-CT,

[0354] A portion of the stained sample is imaged using a Bruker SkyScan Model 1272 micro-CT or equivalent. Exemplary x-ray scan conditions include the following:

[0355] - Voltage (kV) = 35

[0356] - Current (uA) = 231

[0357] - Image pixel size (um) = 8.0

[0358] - Rotation step (degrees) = 0.20

[0359] - Frame averaging = 5

[0360] The sample must be oriented so that the machine direction length remains in the vertical position during the scanning process. After the initial x-ray scan, the rotated x-ray images are then reconstructed using Bruker's NRecon software or equivalent on other vendor systems. The grayscale reconstructed image slices are used for adhesive distribution analysis.

[0361] The image analysis software platform used to perform the adhesive distribution measurements can be QWIN Pro (version 3.2.1) available from Leica Microsystems (with offices in Heerbrugg, Switzerland). Using the Quantimet User Interactive Programming System (QUIPS) language, the grayscale micro-CT images are processed and measurements performed using a custom written image analysis algorithm "Z-Adhesive Distribution." The custom image analysis algorithm shown below is executed directly on the grayscale reconstructed image slices stored on a storage device. The custom image analysis algorithm is shown below.

[0362] Name: z-Adhesive Distribution

[0363] Purpose: Measure the z-distribution of osmium stained adhesive on ActivTech / Blizzard substrate

[0364] Conditions: Images acquired on a Bruker SkyScan 1272 micro-CT

[0365] Date: August 12, 2020

[0366] Author: D.G. Biggs

[0367] Settings

[0368] Clear Accept

[0369] Open data file

[0370] Open file (C:\Data\102888-Graverson\totdistribution.xls, Channel #2)

[0371] Open file (C:\Data\102888-Graverson\adhesivedistribution.xls, Channel #1)

[0372] Configure (Image memory 1968 x 504, grayscale image 201, binary 32)

[0373] --Calvalue = 8.00 um / px

[0374] Calculated value = 8.00

[0375] Correct (Calculated value calculation unit $ per pixel)

[0376] Measure frame (x 160, y 2, width 1600, height 502)

[0377] Image frame (x 0, y 0, width 1968, height 504)

[0378] Enter result header

[0379] File result header (Channel #1)

[0380] File row (Channel #1)

[0381] File result header (Channel #2)

[0382] File row (Channel #2)

[0383] Pause text ("Enter sample image file prefix name.")

[0384] Enter (Title $)

[0385] File (Title $, Channel #1)

[0386] File line (channel #1)

[0387] For (image = 100 to 900, step 100)

[0388] Clear feature histogram #1

[0389] Clear feature histogram #3

[0390] Define binary graphic variable

[0391] GRAPHORGX = 250

[0392] Image acquisition and detection

[0393] ACQOUTPUT = 0

[0394] - Location of micro-CT image to be analyzed

[0395] ACQFILE$ = "C:\Images\102888-Graverson\Code 2-Blizzard Tech Osmium\" + TITLE$ + "" + STR$(IMAGE) + ".JPG"

[0396] Read image (from file ACQFILE$ to ACQOUTPUT)

[0397] Color transform (monochrome mode)

[0398] - Detect all materials

[0399] Detect (whiter than 33, from image 0 to binary 0)

[0400] Image processing

[0401] PauseText("Accept main structure, exclude any peripheral debris.")

[0402] Binary edit [pause] (accept from binary 0 to binary 1, nibble fill, width 2)

[0403] Binary modify (from binary 1 to binary 1 on, loop 1, operator disk, edge erosion on)

[0404] Binary modify (from binary 1 to binary 2 off, loop 120, operator disk, edge erosion on)

[0405] Binary identify (fill holes from binary 2 to binary 3)

[0406] Binary modify (from binary 3 to binary 4 on, loop 5, operator disk, edge erosion on)

[0407] Boolean and Measure

[0408] For (BINGRAPH = 1 to 26, Step 1)

[0409] GRAPHORGY = 2

[0410] GRAPHNX = 1

[0411] GRAPHNY = 1

[0412] GRAPHWID = 50

[0413] GRAPHHGHT = 502

[0414] GRAPHTHIK = 1

[0415] GRAPHORNT = 0

[0416] GRAPHOUT = 13

[0417] Graph (inverted grid, GRAPHNX x GRAPHNY lines, grid size GRAPHWID x GRAPHHGHT, origin GRAPHORGX x GRAPHORGY,

[0418] thickness GRAPHTHIK, orientation GRAPHORNT, to GRAPHOUT clear)

[0419] Binary logic (C = A AND B: C binary 5, A binary 4, B binary 13)

[0420] Center YPOS

[0421] Measure feature (planar binary 5, 32 feret, minimum area: 10, grayscale image: color 0)

[0422] Selected parameters: UserDef1, YCentroid

[0423] Feature expression (UserDef1 (all features), title CalcA = (py centroid (FTR) - 252))

[0424] GREYUTILIN = 0

[0425] GREYUTILOUT = 1

[0426] - Transfer grayscale image

[0427] If (PUSERDEF1 (FTR) < 0)

[0428] Distance = (PUSERDEF1 (FTR) ** 2) ** 0.5

[0429] SHIFT. SIZE = Distance

[0430] SHIFT. DIRN = 270

[0431] Grey Util (Shift GREYUTILIN to GREYUTILOUT by SHIFT. SIZE at SHIFT. DIRN degs)

[0432] Endif

[0433] If (PUSERDEF1 (FTR) > 0)

[0434] Distance = PUSERDEF1 (FTR)

[0435] SHIFT. SIZE = Distance

[0436] SHIFT. DIRN = 90

[0437] Grey Util (Shift GREYUTILIN to GREYUTILOUT by SHIFT. SIZE at SHIFT. DIRN degs)

[0438] Endif

[0439] If (PUSERDEF1 (FTR) = 0)

[0440] Grey Util (Copy image 0 to image 1)

[0441] Endif

[0442] Show (image 0 (on), frame (on, on), plane (off, off, off, off, off, off), lut 0, x 0, y 0, z 1, shrink off)

[0443] Centered detection

[0444] - Detect adhesive

[0445] Detect (whiter than 84, from image 1 to binary 10)

[0446] Binary modify (from binary 10 to binary 10 off, loop 1, operator disk, edge erosion on)

[0447] Binary modify (from binary 10 to binary 11 off, loop 1, operator disk, edge erosion on)

[0448] - Detect All Materials

[0449] Detect (whiter than 33, from image 1 to binary 0)

[0450] Binary Modify (from binary 0 to binary 0 off, loop 1, operator disk, edge erosion on)

[0451] Binary Modify (from binary 0 to binary 0 on, loop 1, operator disk, edge erosion on)

[0452] Measure Z Distribution of Adhesive

[0453] GRAPHORGY = 2

[0454] GRAPHNX = 1

[0455] GRAPHNY = 1

[0456] GRAPHWID = 50

[0457] GRAPHHGHT = 502

[0458] GRAPHTHIK = 1

[0459] GRAPHORNT = 0

[0460] GRAPHOUT = 12

[0461] Graph (inverted grid, GRAPHNX x GRAPHNY lines, grid size GRAPHWID x GRAPHHGHT, origin GRAPHORGX x GRAPHORGY,

[0462] Thickness GRAPHTHIK, orientation GRAPHORNT, to GRAPHOUT clear)

[0463] Binary Logic (C = A AND B: C binary 6, A binary 12, B binary 11)

[0464] Measure Feature (planar binary 6, 32 feret, minimum area: 10, grayscale image: image 1)

[0465] Selected Parameters: Area, UserDef2, YCentroid

[0466] Feature Expression (UserDef2 (all features), title YFEAT = py centroid (FTR) * calvalue)

[0467] Feature Histogram #1 (Y Param Area, X Param UserDef2, from 0. to 4032., linear, 40 bins)

[0468] Feature Histogram #2 (Y Param Area, X Param UserDef2, from 0. to 4032., linear, 40 bins)

[0469] Measure Total Material Z Distribution

[0470] Binary Logic (C = A and B: C binary 7, A binary 12, B binary 0)

[0471] Measure Feature (Planar binary 7, 32 feret, min area: 10, gray scale image: Image 1)

[0472] Selected Parameters: Area, X FCP, Y FCP, UserDef2, Y Centerline

[0473] Feature Expression (UserDef2 (all features), title YFEAT = py centroid (FTR) * calvalue)

[0474] Feature Histogram #3 (Y Param Area, X Param UserDef2, from 0. to 4032., linear, 40 bins)

[0475] Feature Histogram #4 (Y Param Area, X Param UserDef2, from 0. to 4032., linear, 40 bins)

[0476] GRAPHORGX = GRAPHORGX + 50

[0477] Next (BINGRAPH)

[0478] Display Feature Histogram Results (#2, horizontal, differential, bins + graph (Y axis linear), statistics)

[0479] Data Window (10, 871, 640, 300)

[0480] Display Feature Histogram Results (#4, horizontal, differential, bins + graph (Y axis linear), statistics)

[0481] Data Window (962, 880, 640, 300)

[0482] Archive Adhesive and Material Histograms for Current Image

[0483] File Feature Histogram Results (#1, differential, statistics, bins details, channel #1)

[0484] File Line (Channel #1)

[0485] File Feature Histogram Results (#3, Differential, Statistics, Bin Details, Channel #2)

[0486] File Line (Channel #2)

[0487] File Line (Channel #2)

[0488] Measure Average Base Thickness

[0489] MFLDIMAGE = 4

[0490] Measure Field (Plane MFLDIMAGE, Into FLDRESULTS (1), Statistics Into FLDSTATS (7,1))

[0491] Selected Parameter: Area

[0492] Average Thickness = Field Results (1) / (CALVALUE * 1330)

[0493] File ("Average Base Thickness (um) = ", Channel #1)

[0494] File (MEANTHICK, Channel #1, 2 Digits after '.')

[0495] File Line (Channel #1)

[0496] File Line (Channel #1)

[0497] Next (Image)

[0498] Adhesive and Material Histograms Accumulated for Current Slide Archive

[0499] File Feature Histogram Results (#2, Differential, Statistics, Bin Details, Channel #1)

[0500] File Feature Histogram Results (#4, Differential, Statistics, Bin Details, Channel #2)

[0501] Close Data File

[0502] Close File (Channel #1)

[0503] Close File (Channel #2)

[0504] End

[0505] The z-direction adhesive distribution data was exported directly into an EXCEL spreadsheet. For the data acquired from each analyzed slice of the micro-CT image, separate adhesive and total material z-distribution histograms were exported, as well as cumulative histograms from the data of all nine slices. These latter cumulative histograms were used to calculate the percent adhesive in each third of the micro-CT image thickness of the individual slices. The area units shown in the histograms are square microns. To determine the histogram locations of the top and bottom surface boundaries of the material, a 95 weight percent total area rule was used on the total material histogram. In other words, when approaching the top and bottom material edges of the histogram, the surface boundary was considered to be the first histogram bin when a minimum of 2.5 weight percent of the material area was encountered. These bin boundaries were then transposed onto the adhesive-only cumulative histogram to determine the percent adhesive area present in the top, middle, and bottom third histogram bins, including the calculated boundary bins. In the event that the number of bins was not divisible by 3 (e.g., 8, 10, 14, etc.), a rotation technique was used to calculate the percent adhesive in each third of the material. For example, on the first encounter of a 14 bin thickness, the top layer was 4 bins, the middle was 5 bins, and the bottom was 5 bins. On the next encounter, the top layer was five bins, the middle was four bins, and the bottom was five bins. If a third encounter occurred, the bottom layer would be one or more bins less than the top and middle layers. If a fourth encounter occurred, the top layer again became the layer containing one or more bins less than the other two layers. This rotation method continued as required by the data.

[0506] The final sample average adhesive percent values for each third of the z-distribution depth were based on N=7 analyses from seven separate subsampling zones, each zone having four adjacent cut cross sections. Student T analysis at a 90% confidence level can be used for comparisons between different samples.

[0507] The relevant portions of all documents cited in the specific embodiments are incorporated by reference herein; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this written document conflicts with any meaning or definition of the term in a document incorporated by reference, the meaning or definition assigned to the term in this written document shall prevail.

[0508] While particular embodiments of the present application have been shown and described, it will be obvious to those skilled in the art that, based upon the teachings herein, changes and modifications can be made in the apparatus and process described without departing from the spirit and scope of the application. Accordingly, it is intended to cover all such changes and modifications that are within the scope of the application, as defined in the appended claims.

[0509] ​

[0510] In a first embodiment, a method of making an absorbent structure can comprise: directing a first stream of superabsorbent particles toward a first layer of substrate material moving in a machine direction, the first stream of superabsorbent particles having a first side and a second side, spraying a first adhesive toward the first side of the first stream of superabsorbent particles with a first adhesive applicator having a first adhesive nozzle, the first adhesive contacting the first stream of superabsorbent particles and mixing with the superabsorbent particles of the first stream of superabsorbent particles before the superabsorbent particles are deposited onto the first layer of substrate material, the first adhesive contacting the first stream of superabsorbent particles at a first point of contact having a first height measured from the first layer of substrate material, spraying a second adhesive toward the second side of the first stream of superabsorbent particles with a second adhesive applicator having a second adhesive nozzle, the second adhesive contacting the first stream of superabsorbent particles and mixing with the superabsorbent particles of the first stream of superabsorbent particles before the superabsorbent particles are deposited onto the first layer of substrate material, the second adhesive contacting the first stream of superabsorbent particles at a second point of contact having a second height measured from the first layer of substrate material, the first height being different than the second height, depositing the mixed superabsorbent particles, first adhesive, and second adhesive of the first stream of superabsorbent particles onto the first layer of substrate material, and covering the mixture of the superabsorbent particles, the first adhesive, and the second adhesive of the first stream of superabsorbent particles with a second layer of substrate material.

[0511] In a second embodiment, the first side of the first stream of superabsorbent particles of the first embodiment can be upstream of the second side of the first stream of superabsorbent particles in the machine direction, and wherein the first point of contact is closer to the first layer of substrate material than the second point of contact.

[0512] In a third embodiment, the first side of the first stream of superabsorbent particles of the first embodiment can be upstream of the second side of the first stream of superabsorbent particles in the machine direction, and wherein the first point of contact is further from the first layer of substrate material than the second point of contact.

[0513] In a fourth embodiment, the first height of any of the first through third embodiments can be between 4 mm and 40 mm from the first layer of substrate material.

[0514] In a fifth embodiment, the first height of any of the first through third embodiments can be spaced between 3 mm and 9.5 mm from the second height.

[0515] In a sixth embodiment, the first adhesive applicator of any of the first through fifth embodiments can be oriented at a first angle between 45 degrees and 75 degrees relative to the machine direction.

[0516] In a seventh implementation, the second adhesive applicator of the sixth implementation can be oriented at a second angle relative to the machine direction between 45 degrees and 75 degrees, and wherein the first angle is the same as the second angle.

[0517] In an eighth implementation, the method of any of the first through seventh implementations, prior to covering the mixture of the superabsorbent particles of the first stream of superabsorbent particles, the first adhesive, and the second adhesive with the second layer of base material, can further comprise: directing a second stream of superabsorbent particles toward the mixture of the superabsorbent particles of the first stream of superabsorbent particles, the first adhesive, and the second adhesive, the second stream of superabsorbent particles having a first side and a second side; spraying a third adhesive with a third adhesive applicator having a third adhesive nozzle toward the first side of the second stream of superabsorbent particles, the third adhesive contacting the superabsorbent particles of the second stream of superabsorbent particles and mixing with the superabsorbent particles of the second stream of superabsorbent particles prior to the superabsorbent particles being deposited onto the mixture of the superabsorbent particles of the first stream of superabsorbent particles, the first adhesive, and the second adhesive; spraying a fourth adhesive with a fourth first adhesive applicator having a second adhesive nozzle toward the second side of the second stream of superabsorbent particles, the fourth adhesive contacting the superabsorbent particles of the second stream of superabsorbent particles and mixing with the superabsorbent particles of the second stream of superabsorbent particles prior to the superabsorbent particles being deposited onto the mixture of the superabsorbent particles of the first stream of superabsorbent particles, the first adhesive, and the second adhesive; and depositing the mixed superabsorbent particles, third adhesive, and fourth adhesive of the second stream of superabsorbent particles onto the mixture of the superabsorbent particles of the first stream of superabsorbent particles, the first adhesive, and the second adhesive.

[0518] In a ninth implementation, the method of the eighth implementation can further comprise wherein: the third adhesive contacts the second stream of superabsorbent particles at a third contact point having a third height measured from the first layer of base material, the fourth adhesive contacts the second stream of superabsorbent particles at a fourth contact point having a fourth height measured from the first layer of base material, and the third height is different than the fourth height.

[0519] In a tenth implementation, the method of any of the first through ninth implementations can further comprise cutting the first layer of material, the mixture of the superabsorbent particles of the first stream of superabsorbent particles, the first adhesive, and the second adhesive, and the second layer of base material into individual absorbent structures.

[0520] In an eleventh embodiment, a method of making an absorbent structure can comprise: directing a first stream of superabsorbent particles toward a first layer of substrate material, the first stream of superabsorbent particles having a first side and a second side; spraying a first adhesive toward the first side of the first stream of superabsorbent particles with a first adhesive applicator having a first adhesive nozzle, the first adhesive contacting the first stream of superabsorbent particles and mixing with the superabsorbent particles of the first stream of superabsorbent particles before the superabsorbent particles are deposited onto the first layer of substrate material; depositing the mixed superabsorbent particles of the first stream of superabsorbent particles and the first adhesive onto the first layer of substrate material; directing a second stream of superabsorbent particles toward the deposited mixture of the superabsorbent particles of the first stream of superabsorbent particles and the first adhesive, the second stream of superabsorbent particles having a first side and a second side; spraying a second adhesive toward one of the first side and the second side of the second stream of superabsorbent particles with a second adhesive applicator having a second adhesive nozzle, the second adhesive contacting the second stream of superabsorbent particles and mixing with the superabsorbent particles of the second stream of superabsorbent particles before the superabsorbent particles are deposited onto the deposited mixture of the superabsorbent particles of the first stream of superabsorbent particles and the first adhesive; depositing the mixed superabsorbent particles of the second stream of superabsorbent particles and the second adhesive onto the deposited mixture of the superabsorbent particles of the first stream of superabsorbent particles and the first adhesive; and covering the deposited mixture of the superabsorbent particles of the first stream of superabsorbent particles and the first adhesive and the superabsorbent particles of the second stream of superabsorbent particles and the second adhesive with a second layer of substrate material.

[0521] In a twelfth embodiment, the method of the eleventh embodiment can further comprise: spraying a third adhesive toward the second side of the first stream of superabsorbent particles with a third adhesive applicator having a third adhesive nozzle, the third adhesive contacting the first stream of superabsorbent particles and mixing with the superabsorbent particles of the first stream of superabsorbent particles before the superabsorbent particles are deposited onto the first layer of substrate material; and spraying a fourth adhesive toward the other of the first side and the second side of the second stream of superabsorbent particles with a fourth adhesive applicator having a fourth adhesive nozzle, the fourth adhesive contacting the second stream of superabsorbent particles and mixing with the superabsorbent particles of the second stream of superabsorbent particles before the superabsorbent particles are deposited onto the deposited mixture of the superabsorbent particles of the first stream of superabsorbent particles and the first adhesive.

[0522] In a thirteenth implementation, the method of the twelfth implementation can further include wherein: the first adhesive contacts the first stream of superabsorbent particles at a first contact point having a first height measured from the first substrate material layer, the third adhesive contacts the first stream of superabsorbent particles at a third contact point having a third height measured from the first substrate material layer, the second adhesive contacts the second stream of superabsorbent particles at a second contact point having a second height measured from the first substrate material layer, the fourth adhesive contacts the second stream of superabsorbent particles at a fourth contact point having a fourth height measured from the first substrate material layer, and the first height is different than the third height, and the second height is different than the fourth height.

[0523] In a fourteenth implementation, the method of any of the eleventh through thirteenth implementations can include, wherein the first stream of superabsorbent particles is fed such that the superabsorbent particles of the first stream of superabsorbent particles create a first layer of superabsorbent particles having a basis weight of superabsorbent particles between 100 gsm and 300 gsm, and wherein the second stream of superabsorbent particles is fed such that the superabsorbent particles of the second stream of superabsorbent particles create a second layer of superabsorbent particles having a basis weight of superabsorbent particles between 100 gsm and 300 gsm.

[0524] In a fifteenth implementation, the method as described in the fourteenth implementation, wherein the first layer of superabsorbent particles formed from the deposited superabsorbent particles of the first stream of superabsorbent particles and the second layer of superabsorbent particles formed from the deposited superabsorbent particles of the second stream of superabsorbent particles differ by less than 50 gsm in basis weight of superabsorbent particles.

[0525] In a sixteenth implementation, the method of the fourteenth or fifteenth implementation can further include, wherein an amount of adhesive mixed with the superabsorbent particles of the first layer of superabsorbent particles is between 2% and 9% by weight of the weight of the superabsorbent particles within the first layer of superabsorbent particles, and wherein an amount of adhesive mixed with the superabsorbent particles of the second layer of superabsorbent particles is between 2% and 9% by weight of the weight of the superabsorbent particles within the second layer of superabsorbent particles.

[0526] In a seventeenth implementation, the method of the fourteenth or fifteenth implementation can further include, wherein an amount of adhesive mixed with the superabsorbent particles of the first layer of superabsorbent particles is between 3% and 7% by weight of the weight of the superabsorbent particles within the first layer of superabsorbent particles, and wherein an amount of adhesive mixed with the superabsorbent particles of the second layer of superabsorbent particles is between 3% and 7% by weight of the weight of the superabsorbent particles within the second layer of superabsorbent particles.

[0527] In an eighteenth implementation, the method of any of the eleventh through seventeenth implementations can further include, wherein the first stream of superabsorbent particles is fed such that the superabsorbent particles of the first stream of superabsorbent particles create a first layer of superabsorbent particles having a basis weight of superabsorbent particles between 100 gsm and 250 gsm, and wherein the second stream of superabsorbent particles is fed such that the superabsorbent particles of the second stream of superabsorbent particles create a second layer of superabsorbent particles having a basis weight of superabsorbent particles between 100 gsm and 250 gsm.

[0528] In a nineteenth implementation, a method of making an absorbent structure can include: directing a first stream of superabsorbent particles toward a first layer of substrate material, the first stream of superabsorbent particles having a first side and a second side, wherein the first stream of superabsorbent particles is fed such that the superabsorbent particles of the first stream of superabsorbent particles create a first layer of superabsorbent particles having a basis weight of superabsorbent particles greater than 200 gsm, spraying a first adhesive with a first adhesive applicator having a first adhesive nozzle toward the first side of the first stream of superabsorbent particles, the first adhesive contacting the first stream of superabsorbent particles and mixing with the superabsorbent particles of the first stream of superabsorbent particles before the superabsorbent particles are deposited onto the first layer of substrate material, spraying a second adhesive with a second first adhesive applicator having a second adhesive nozzle toward the second side of the first stream of superabsorbent particles, the second adhesive contacting the first stream of superabsorbent particles and mixing with the superabsorbent particles of the first stream of superabsorbent particles before the superabsorbent particles are deposited onto the first layer of substrate material, depositing the mixed superabsorbent particles, first adhesive, and second adhesive of the first stream of superabsorbent particles onto the first layer of substrate material, wherein the total amount of adhesive mixed with the superabsorbent particles of the first layer of superabsorbent particles is less than 5 wt.% of the weight of the superabsorbent particles within the first layer of superabsorbent particles, and covering the mixture of the superabsorbent particles, the first adhesive, and the second adhesive of the first stream of superabsorbent particles with a second layer of substrate material.

[0529] In a twentieth implementation, the method of the nineteenth implementation can further include, wherein the total amount of adhesive mixed with the superabsorbent particles of the first layer of superabsorbent particles is less than 4 wt.% of the weight of the superabsorbent particles within the first layer of superabsorbent particles.

[0530] In a twenty-first implementation, the method of the nineteenth or twentieth implementation, prior to covering the mixture of the superabsorbent particles of the first stream of superabsorbent particles, the first binder, and the second binder with a second layer of substrate material, can further comprise: directing a second stream of superabsorbent particles toward the mixture of the superabsorbent particles of the first stream of superabsorbent particles, the first binder, and the second binder, the second stream of superabsorbent particles having a first side and a second side, wherein the second stream of superabsorbent particles is fed such that the superabsorbent particles of the second stream of superabsorbent particles create a second layer of superabsorbent particles having a basis weight of superabsorbent particles greater than 200 gsm, spraying a third binder with a third binder applicator having a third binder nozzle toward one of the first side and the second side of the second stream of superabsorbent particles, the third binder contacting the second stream of superabsorbent particles and mixing with the superabsorbent particles of the second stream of superabsorbent particles prior to the superabsorbent particles being deposited onto the mixture of the superabsorbent particles of the first stream of superabsorbent particles, the first binder, and the second binder, spraying a fourth binder with a fourth first binder applicator having a fourth binder nozzle toward the other of the first side and the second side of the second stream of superabsorbent particles, the fourth binder contacting the second stream of superabsorbent particles and mixing with the superabsorbent particles of the second stream of superabsorbent particles prior to the superabsorbent particles being deposited onto the mixture of the superabsorbent particles of the first stream of superabsorbent particles, the first binder, and the second binder, and depositing the mixed superabsorbent particles, third binder, and fourth binder of the second stream of superabsorbent particles onto the mixture of the superabsorbent particles of the first stream of superabsorbent particles, the first binder, and the second binder, wherein the total amount of binder mixed with the superabsorbent particles of the second layer of superabsorbent particles is less than 5 wt.% of the weight of the superabsorbent particles within the second layer of superabsorbent particles.

[0531] In a twenty-second implementation, the method of the twenty-first implementation can further comprise, wherein the total amount of binder mixed with the superabsorbent particles of the second layer of superabsorbent particles is less than 4 wt.% of the weight of the superabsorbent particles within the second layer of superabsorbent particles.

[0532] In a twenty-third implementation, the method of any of the nineteenth through twenty-second implementations can further comprise, wherein the first stream of superabsorbent particles is fed such that the superabsorbent particles of the first stream of superabsorbent particles create a first layer of superabsorbent particles having a basis weight of superabsorbent particles greater than or equal to 250 gsm.

[0533] In a twenty-fourth embodiment, the method of any of the twenty-first through twenty-third embodiments can further include, wherein the second stream of superabsorbent particles is fed such that the superabsorbent particles of the second stream of superabsorbent particles create a second superabsorbent particle layer having a basis weight of greater than or equal to 250 gsm of superabsorbent particles.

Claims

1. A method for manufacturing an absorber structure, the method comprising: A first superabsorbent particle stream is directed to a first substrate material layer moving in the machine direction, the first superabsorbent particle stream having a first side and a second side. A first adhesive is sprayed onto the first side of the first superabsorbent particle stream using a first adhesive applicator having a first adhesive nozzle. The first adhesive contacts the first superabsorbent particle stream and mixes with the superabsorbent particles of the first superabsorbent particle stream before the superabsorbent particles are deposited onto the first substrate material layer. The first adhesive contacts the first superabsorbent particle stream at a first contact point having a first height measured from the first substrate material layer. A second adhesive is sprayed onto the second side of the first superabsorbent particle stream using a second adhesive applicator having a second adhesive nozzle. The second adhesive contacts the first superabsorbent particle stream and mixes with the superabsorbent particles of the first superabsorbent particle stream before the superabsorbent particles are deposited onto the first substrate material layer. The second adhesive contacts the first superabsorbent particle stream at a second contact point having a second height measured from the first substrate material layer, the first height being different from the second height. The superabsorbent particles, the first binder, and the second binder of the first superabsorbent particle stream are deposited onto the first substrate material layer. as well as The mixture of the superabsorbent particles, the first adhesive, and the second adhesive of the first superabsorbent particle stream is covered with a second base material layer; The first side of the first superabsorbent particle stream is located upstream of the second side of the first superabsorbent particle stream in the machine direction, and the first contact point is closer to the first substrate material layer than the second contact point. Alternatively, the first side of the first superabsorbent particle stream is located upstream of the second side of the first superabsorbent particle stream in the machine direction, and the first contact point is farther away from the first substrate material layer than the second contact point.

2. The method of claim 1, wherein the first height is located between 4 mm and 40 mm from the first substrate material layer.

3. The method of claim 1, wherein the first height and the second height are spaced between 3 mm and 9.5 mm apart.

4. The method of claim 1, wherein the first adhesive applicator is oriented at a first angle between 45 degrees and 75 degrees relative to the machine direction.

5. The method of claim 4, wherein the second adhesive applicator is oriented at a second angle between 45 and 75 degrees relative to the machine direction, and wherein the first angle is the same as the second angle.

6. The method of claim 1, further comprising, before covering the mixture of the superabsorbent particles, the first adhesive, and the second adhesive of the first superabsorbent particle stream with a second substrate material layer: A mixture of superabsorbent particles, the first binder, and the second binder that guides the second superabsorbent particle stream into the first superabsorbent particle stream, the second superabsorbent particle stream having a first side and a second side; A third adhesive is sprayed onto the first side of the second superabsorbent particle stream using a third adhesive applicator with a third adhesive nozzle. The third adhesive contacts the second superabsorbent particle stream and mixes with the superabsorbent particles of the second superabsorbent particle stream before the superabsorbent particles are deposited onto the mixture of the superabsorbent particles, the first adhesive, and the second adhesive in the first superabsorbent particle stream. A fourth adhesive is sprayed onto the second side of the second superabsorbent particle stream using a fourth first adhesive applicator having a second adhesive nozzle. The fourth adhesive contacts the second superabsorbent particle stream and mixes with the superabsorbent particles of the second superabsorbent particle stream before the superabsorbent particles are deposited onto the mixture of the superabsorbent particles, the first adhesive, and the second adhesive in the first superabsorbent particle stream. as well as The superabsorbent particles, the third binder, and the fourth binder of the second superabsorbent particle stream are deposited onto the mixture of the superabsorbent particles, the first binder, and the second binder of the first superabsorbent particle stream.

7. The method of claim 6, wherein: The third adhesive contacts the second superabsorbent particle stream at a third contact point having a third height measured from the first substrate material layer. The fourth adhesive contacts the second superabsorbent particle stream at a fourth contact point having a fourth height measured from the first substrate material layer, and The third altitude is different from the fourth altitude.

8. The method of claim 1, further comprising cutting the first material layer, the superabsorbent particles of the first superabsorbent particle stream, the mixture of the first adhesive and the second adhesive, and the second substrate material layer into separate absorbent structures.

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