Absorbent structures and methods of making absorbent structures

Abstract

Absorbent structures and methods of manufacture are disclosed. In one embodiment, an absorbent structure can include a first layer, a second layer, and a mixture of particles and adhesive between the first layer and the second layer, wherein the particles are disposed at a weight greater than 400 gsm and less than 600 gsm, wherein the adhesive is disposed at a weight greater than 4% and less than 6% of the weight of the particles, wherein the adhesive forms a three-dimensional network structure including network adhesive filaments, the particles are immobilized within the network structure, and the network adhesive filaments extend substantially in three-dimensional space defined by the network adhesive filaments and the particles, the structure having a Gray Level % Coefficient of Variation value (GL % COV) of less than or equal to 34.5 according to the Pad Uniformity Test Method.

Description

Technical Field

[0001] This disclosure relates to absorption structures, and more specifically to absorption structures having a high content of superabsorbent material. Background Technology

[0002] The primary function of personal care absorbent products is to absorb and retain bodily fluids such as urine, feces, blood, and menstrual flow. They also possess additional desirable properties, including minimal leakage and a dry feel for the wearer. By preventing leakage, absorbent products aim to prevent bodily fluids from soiling or contaminating the wearer's or caregiver's clothing or other items that may come into contact with the wearer, such as bedding.

[0003] Absorbent cores typically help absorb and retain liquids within absorbent materials. 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 helps to give such absorbent cores a range of properties that can be used to absorb and retain liquid bodily effluents. For example, pulp fluff or other fibrous absorbent materials can absorb liquids faster than superabsorbent materials, and superabsorbent materials can retain more liquid per particle than pulp fluff.

[0004] Significant progress has been made in absorbent cores, particularly in superabsorbent materials. Some current absorbent cores may now have absorbent materials that primarily consist of superabsorbent materials and further include only a small portion of other absorbent materials. Other current absorbent cores contain only superabsorbent materials as absorbent materials. There is a growing need for further development of absorbent cores with high superabsorbent material content to further improve the performance of such absorbent cores. Summary of the Invention

[0005] This disclosure discloses an absorbent structure and a method for manufacturing such an absorbent structure. In a first embodiment, an absorbent structure having a longitudinal axis and a transverse axis may include: a first substrate material layer having a first surface and a second surface; a second substrate material layer having a first surface and a second surface; and a mixture of superabsorbent particles and an adhesive disposed between the first substrate material layer and the second substrate material layer, wherein the superabsorbent particles are disposed in an amount greater than or equal to 400 gsm and less than or equal to 600 gsm, and wherein the adhesive is disposed in an amount greater than or equal to 4% by weight and less than or equal to 6% by weight of the superabsorbent particles, wherein the adhesive forms a three-dimensional mesh structure comprising mesh adhesive filaments, the superabsorbent particles being fixed within the mesh structure, and the mesh adhesive filaments extending substantially in a three-dimensional space defined by the mesh adhesive filaments and the superabsorbent particles, and wherein, according to a pad uniformity test method, the absorbent structure has a gray-level % coefficient of variation (GL%COV) value less than or equal to 34.5.

[0006] In a second embodiment, an absorbent structure having a longitudinal axis and a transverse axis may include: a first base material layer having a first surface and a second surface; a second base material layer having a first surface and a second surface; and a mixture of superabsorbent particles and an adhesive disposed between the first base material layer and the second base material layer, wherein the superabsorbent particles are disposed in an amount greater than or equal to 400 gsm and less than or equal to 500 gsm, and wherein the adhesive is disposed in an amount greater than or equal to 4% by weight and less than or equal to 6% by weight of the superabsorbent particles, wherein the adhesive forms a three-dimensional mesh structure comprising mesh adhesive filaments, the superabsorbent particles being fixed within the mesh structure, and the mesh adhesive filaments extending substantially in a three-dimensional space defined by the mesh adhesive filaments and the superabsorbent particles, and wherein, according to a pad uniformity test, the absorbent structure has a CD gray level variation (CD GLVar.) value less than or equal to 510.

[0007] In a third embodiment, a method of manufacturing an absorbent structure may include: supplying a first superabsorbent particle stream to a first substrate material layer moving in a machine direction, the first superabsorbent particle stream having a first side and a second side; 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; the first adhesive contacting the first superabsorbent particle stream at a first contact point having a first height measured from the first substrate material layer; and spraying a second adhesive onto the second side of the first superabsorbent particle stream using a second adhesive applicator having a second adhesive nozzle, the second adhesive contacting the first superabsorbent particle stream and mixing with the first superabsorbent particles of the first superabsorbent particle stream before the superabsorbent particles are deposited onto the first substrate material layer. The superabsorbent particles of the absorbent particle stream are mixed, and the second binder contacts the first superabsorbent particle stream at a second contact point having a second height measured from the first substrate material layer. The mixed superabsorbent particles of the first superabsorbent particle stream, the first binder, and the second binder are deposited onto the first substrate material layer. The mixture of the superabsorbent particles, the first binder, and the second binder of the first superabsorbent particle stream is covered with a second substrate material layer. The mixture of the superabsorbent particles, the binder, the first substrate material layer, and the second substrate material layer is separated into individual absorbent structures. The absorbent structure prepared by the method, having superabsorbent particles set in an amount equal to 300 gsm and binder set in an amount greater than 3% by weight and less than 4% by weight of the superabsorbent particles, has a CD gray level variation (CD GL Var.) value of less than or equal to 675, according to the pad uniformity test. 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 4It 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 This is a schematic diagram depicting an exemplary method for manufacturing an absorbent structure according to the present disclosure.

[0015] Figure 7 It is a description Figure 6 A process diagram of a portion of an exemplary method.

[0016] Figure 8 This is a schematic diagram depicting an alternative exemplary method for manufacturing an absorbent structure according to the present disclosure.

[0017] Figures 9A to 9C It is along Figure 8 Line 9-9 shows different exemplary front cross-sectional views of the absorption structure formed according to the manufacturing method of this disclosure.

[0018] Figures 10A to 10B It is along Figure 8 The following are different exemplary front cross-sectional views of the absorption structure formed according to the manufacturing method of this disclosure, taken from line 10-10.

[0019] Figure 11A It is based on the various aspects of this disclosure used for analysis. Figure 8 The top perspective view of a three-dimensional image generated by a micro-CT process of an exemplary mixture of particles and adhesive filaments formed during the process.

[0020] Figure 11B yes Figure 11A The top plan view of the 3D image.

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

[0022] Figure 11D yes Figure 11C A cross-sectional view showing that the particles leave only adhesive filaments.

[0023] The repeated use of reference numerals in this specification and drawings is intended to indicate the same or similar features or elements of this disclosure. Detailed Implementation

[0024] In one embodiment, this disclosure generally relates to absorbent core materials comprising a high proportion of superabsorbent material. Each example is given by way of illustration and is not intended to be limiting. For example, features illustrated or described as part of one embodiment or drawing may be used in another embodiment or drawing to produce yet another embodiment. It is intended that this disclosure contain such modifications and variations.

[0025] When describing elements of this disclosure or its preferred embodiments, the articles “a,” “an,” “the,” and “the” are intended to indicate the presence of one or more of the element. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that additional elements besides those listed may be present. Many modifications and variations may be made to this disclosure without departing from its spirit and scope. Therefore, the exemplary embodiments described above should not be used to limit the scope of the invention.

[0026] definition:

[0027] The term "absorbent article" herein refers to an article that can be placed close to or near the wearer's body (i.e., adjacent to the body) to absorb and contain various liquid, solid, and semi-solid excretions from the body. Such absorbent articles as described herein are intended to be discarded after their limited use period, rather than washed or otherwise restored for reuse. It should be understood that, without departing from the scope of this disclosure, this disclosure applies to a wide range of disposable absorbent articles, including but not limited to diapers, diaper pants, training pants, baby pants, swim trunks, feminine hygiene products (including but not limited to menstrual pads or menstrual pants), incontinence products and other adult care clothing, medical clothing, surgical pads and bandages, and other personal care or health care clothing.

[0028] The term "collection layer" in this document refers to a layer that can receive and temporarily retain liquid body effluent to slow and diffuse the outflow or burst of liquid body effluent and from which the liquid body effluent is subsequently released into another layer or multiple layers of absorbent article.

[0029] The terms “bonding” or “joining” in this document refer to the joining, adhesion, connection, attachment, etc., of two components. Two components are considered bonded or joined together when they are joined, adhered, connected, attached, etc., directly or indirectly to each other, such as when each component is directly bonded to an intermediate component. Bonding or joining one component to another can be done through continuous or intermittent bonding.

[0030] The term "carded web" in this document refers to a web containing natural or synthetic staple length fibers, typically less than 100 mm in length. Staple fiber bundles may undergo an opening process to separate the fibers, which are then fed to a carding process to separate and card them to align them in the machine direction. Afterward, the fibers are deposited on moving yarns for further processing. Such webs typically undergo some form of bonding process, such as thermal bonding using heat and / or pressure. Alternatively, the fibers may undergo an adhesion process to bond them together, for example, using powdered adhesives. Carded webs may undergo fluid entanglement, such as hydroentangling, to further entangle the fibers and thereby improve the integrity of the carded web. Because the fibers are aligned in the machine direction, carded webs, once bonded, typically have a greater machine direction strength than their cross-machine direction strength.

[0031] "Elastomer" refers to a material or composite that can stretch at least 50% of its relaxed length and recover at least 20% of its elongation after the release of an applied force. Generally preferred is that the elastomeric material or composite is capable of stretching at least 50% of its relaxed length, more preferably at least 100%, and even more preferably at least 300%, and recovering at least 50% of its elongation after the release of an applied force.

[0032] The term "membrane" as used herein refers to a thermoplastic film produced using extrusion and / or forming processes such as cast film or blown film extrusion. This term includes porous membranes, cut films, and other porous membranes constituting liquid transfer membranes, as well as membranes that do not transfer fluids, such as, but not limited to, barrier membranes, filled membranes, breathable membranes, and oriented membranes.

[0033] The term “gsm” in this article refers to grams per square meter.

[0034] The term "hydrophilic" in this document refers to a fiber or fiber surface that is wetted by an aqueous liquid in contact with the fiber. The degree of wettability 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 specific fiber materials or fiber blends are available from the Cahn SFA-222 Surface Force Analyzer System or substantially equivalent systems. When measured using this system, fibers with a contact angle less than 90° are considered "wettable" or hydrophilic, and fibers with a contact angle greater than 90° are considered "non-wettable" or hydrophobic.

[0035] The term "liquid impermeable" herein refers to one or more laminates in which, under normal use conditions, at the point of contact with the liquid, in a direction generally perpendicular to the plane of the layer or laminate, liquid bodily excretions such as urine will not penetrate the layer or laminate.

[0036] The term "liquid-permeable" in this document refers to any material that is not impermeable to liquids.

[0037] The term "meltblown" herein refers to fibers formed by extruding molten thermoplastic material through multiple thin, typically circular, die capillaries into molten wires or filaments and into a converging stream of high-speed heated gas (e.g., air). The high-speed heated gas stream thins the molten thermoplastic material into filaments to reduce their diameter, which may be the diameter of a microfiber. The meltblown fibers are then carried by the high-speed gas stream and deposited onto a collecting surface to form a web composed of randomly dispersed meltblown fibers. This 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 may be continuous or discontinuous, typically less than 0.6 denier, and may be sticky and self-adhesive when deposited on a collecting surface.

[0038] The term "nonwoven" as used herein refers to a material or material web formed without the aid of a weaving or knitting process. The material or material web may have a structure of individual fibers, filaments, or threads (collectively referred to as "fibers"), which may be interlaid, but in a manner distinct from that found in knitted fabrics. Nonwoven materials or webs can be formed by a variety of processes, including, but not limited to, meltblowing, spunbonding, and carding processes.

[0039] The term “flexible” in this article refers to a material that is conformable and easily adapts to the general shape and contours of the wearer’s body.

[0040] The term "spunbond" herein refers to small-diameter fibers formed by extruding molten thermoplastic material as a filament from multiple fine capillaries having a circular or other configuration of spinneret, and then rapidly reducing the diameter of the extruded filament by conventional processes such as draw-out and the processes described in the following patents: U.S. Patent No. 4,340,563 to Appel et al., U.S. Patent No. 3,692,618 to Dorschner et al., U.S. Patent No. 3,802,817 to Matsuki et al., U.S. Patent Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Patent No. 3,502,763 to Hartmann, U.S. Patent No. 3,502,538 to Peterson, and U.S. Patent No. 3,542,615 to Dobo et al., each of which is incorporated herein by reference in its entirety. The spunbond fibers are generally continuous and typically have an average denier greater than 0.3, and in one embodiment between 0.6, 5, and 10 and 15, 20, and 40. The spunbond fibers generally do not become sticky when deposited on a collection surface.

[0041] The term "superabsorbent" herein refers to a water-swellable, water-insoluble organic or inorganic material that, under most favorable conditions, can absorb at least 15 times its own weight, and in one embodiment at least 30 times its own weight, in an aqueous solution containing 0.9 wt% sodium chloride. Superabsorbent materials can be natural, synthetic, and modified natural polymers and materials. Furthermore, superabsorbent materials can be inorganic materials such as silica gel or organic compounds such as crosslinked polymers.

[0042] The term “supermajority” in this article refers to a majority of at least 65%.

[0043] The term "thermoplastic" in this document refers to a material that softens and becomes shapeable when exposed to heat and essentially returns to its unsoftened state upon cooling.

[0044] The terms "user" or "caregiver" in this document refer to a person who applies absorbent materials, such as, but not limited to, diapers, training pants, toddler pants, incontinence products, or other absorbent materials, around the wearer of one of these absorbent materials. The user and the wearer can be the same person.

[0045] Absorbent products:

[0046] See Figure 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 to 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 and 20 may include portions of the front waist piece 13, the absorbent sheet 17, and the rear waist piece 15.

[0049] The front waist area 12 may include a portion of the absorbent articles 10, 210 that, when worn, is at least partially positioned on the front of the wearer; while the back waist area 14 may include a portion of the absorbent articles 10, 210 that, when worn, is at least partially positioned on the back of the wearer. The crotch area 16 of the absorbent articles 10, 210 may include a portion of the absorbent articles 10, 210 that, when worn, is positioned between the wearer's legs and may partially cover the wearer's lower body. The waist edges 22 and 24 of the absorbent articles 10, 210 are configured to surround the wearer's waist and together define a central waist opening 23 (e.g., ...) of the wearer's waist. Figure 1 and Figure 3 (as marked in the text). When absorbent articles 10 and 210 are worn, the portions of the longitudinal side edges 18 and 20 in the crotch area 16 can substantially define the leg openings of the wearer's legs.

[0050] Absorbent articles 10, 210 may include an outer cover 26 and a body side liner 28. The outer cover 26 and the body side liner 28 may form part of a substrate 11. In one embodiment, the body side liner 28 may be bonded to the outer cover 26 in an overlapping 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 may define a length in the longitudinal direction 30 and a width in the transverse direction 32, which in the illustrated embodiment may correspond to the length and width of the absorbent article 10. Figure 2 and Figure 4 As shown, the absorbent articles 10 and 210 may have a longitudinal axis 29 extending in the longitudinal direction 30 and a transverse axis 31 extending in the transverse direction 32.

[0051] The substrate 11 may include an absorbent body 34. The absorbent body 34 may be disposed between the outer cover 26 and the body side liner 28. The absorbent body 34 may have longitudinal edges 36 and 38, which in one embodiment may form portions of the longitudinal side edges 18 and 20 of the absorbent articles 10 and 210, respectively. The absorbent body 34 may have a first end edge 40 correspondingly opposite a second end edge 42, which in one embodiment may form portions of the waist edges 22 and 24 of the absorbent article 10, respectively. In some embodiments, the first end edge 40 may be in the front waist region 12. In some embodiments, the second end edge 42 may be in the rear waist region 14. In one embodiment, the absorbent body 34 may have a length and width that are the same as or smaller than the length and width of the absorbent articles 10 and 210. The body side liner 28, the outer cover 26, and the absorbent body 34 may form part of the absorbent assembly 44. Figure 3 and 4 In the absorbent article 210, the absorbent sheet 17 may form an absorbent assembly 44. As is known in the art, the absorbent assembly 44 may further include a fluid transfer layer 46 (e.g., Figure 5 (as shown in the image) and a fluid collection layer (not shown) located between the body side lining 28 and the fluid transfer layer 46. The absorption assembly 44 may also include a spacer layer 48 (as shown in the image) disposed between the absorption body 34 and the outer cover 26. Figure 5 (as shown in the image).

[0052] Absorbent articles 10, 210 may be configured to contain and / or absorb liquid, solid, and semi-solid bodily excretions from the wearer. In some embodiments, leak-proof flaps 50, 52 may be configured to provide a barrier against lateral flow of bodily excretions. To further enhance the leak-proof and / or absorption effect on bodily excretions, absorbent articles 10, 210 may suitably include a waist leak-proof member 54. In some embodiments, the waist leak-proof member 54 may be disposed in the rear waist region 14 of the absorbent articles 10, 210. Although not shown herein, it is contemplated that the waist leak-proof member 54 may be disposed in the front waist region 12 of the absorbent articles 10, 210 in addition to or as an alternative.

[0053] A waist leak-proof component 54 may be disposed on the body-facing surface 19 of the backing film 11 to help contain and / or absorb bodily fluids. In some embodiments, such as in Figure 1 and Figure 2 In the depicted absorbent article 10, a waist leak-proof member 54 may be disposed on the body-facing surface 45 of the absorbent assembly 44. In some embodiments, the waist leak-proof member 54 may be disposed on the body-facing surface 56 of the side lining 28. In some embodiments, such as in Figure 3 and Figure 4In the absorbent product 210 depicted, a waist leak-proof component 54 may be provided on the body-facing surface 58 of the back waist piece 15.

[0054] The absorbent articles 10, 210 may further include leg elastic members 60, 62 as known to those skilled in the art. The leg elastic members 60, 62 may be attached along opposite longitudinal side edges 18 and 20 to the outer overlay 26 and / or body side lining 28, and positioned in the crotch area 16 of the absorbent articles 10, 210. The leg elastic members 60, 62 may be parallel to the longitudinal axis 29, such as... Figure 2 and 4 As shown in the diagram; or as is known in the art, it can be flexible. The leg elastic members 60, 62 can be elastomers and can be provided as elastic leg clamps.

[0055] In some embodiments, the absorbent articles 10, 210 may further include longitudinally extending fold lines 25a, 25b, such as Figure 2 and Figure 4 As shown in the diagram. A first longitudinally extending fold line 25a may be on one side of the longitudinal axis 29 of the absorbent articles 10, 210, while a second longitudinally extending fold line 25b may be on the opposite side of the longitudinal axis 29. In some embodiments, the longitudinally extending fold lines 25a, 25b may be generally parallel to the longitudinal axis 29 of the absorbent articles 10, 210. In some embodiments, the absorbent articles 10, 210 may further include a laterally extending fold line 27. In some embodiments, the laterally extending fold line 27 may be parallel to and located at the lateral axis 31 of the absorbent articles 10, 210.

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

[0057] Outer coating:

[0058] The outer cover 26 and / or portions thereof may be breathable and / or liquid-impermeable. The outer cover 26 and / or portions thereof may be elastic, stretchable, or non-stretchable. The outer cover 26 may be constructed from a single layer, multiple layers, laminates, spunbond fabric, membrane, meltblown fabric, elastic web, microporous web, bonded carded web, or foam provided by an elastomer or polymer material. In one embodiment, for example, the outer cover 26 may be constructed from a microporous polymer membrane 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, and 210 may cover the absorbent body 34 and the outer cover 26, and may isolate the wearer's skin from waste fluid retained by the absorbent body 34. In various embodiments, a fluid transfer layer 46 may be positioned between the body side liner 28 and the absorbent body 34. In various embodiments, a collection layer (not shown) may 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 may be bonded to the collection layer or the fluid transfer layer 46 (if a collection layer is not present) via an adhesive and / or by point fusion bonding. Point fusion bonding may be selected from ultrasonic bonding, thermal bonding, pressure bonding, and combinations thereof.

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

[0066] The body side lining 28 can be made of various types of materials, such as synthetic fibers (e.g., polyester or polypropylene fibers), natural fibers (e.g., wood or cotton fibers), combinations of natural and synthetic fibers, porous foams, honeycomb foams, porous plastic films, etc. Examples of suitable materials include, but are not limited to, rayon, wood, cotton, polyester, polypropylene, polyethylene, nylon or other thermally 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, porous membrane webs, web materials, etc., and combinations thereof.

[0067] Various woven and nonwoven fabrics may be used for the body side lining 28. The body side lining 28 may include woven fabrics, nonwoven fabrics, polymer films, film-fabric laminates, and combinations thereof. Examples of nonwoven fabrics may include spunbond fabrics, meltblown fabrics, co-formed fabrics, carded webs, bonded carded webs, bicomponent spunbond fabrics, spunlace fabrics, and combinations thereof. The body side lining 28 is not necessarily a single-layer structure and may therefore include more than one layer of fabric, film, and / or web, and combinations thereof. For example, the body side lining 28 may include a support layer and a protruding layer that can be hydrowound. The protruding layer may include hollow protrusions, such as those disclosed in U.S. Patent No. 9,474,660 to Kirby, Scott SC, et al.

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

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

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

[0071] Leak-proof fins:

[0072] In one embodiment, the absorbent articles 10, 210 may include a pair of leak-proof flaps 50, 52. The leak-proof flaps 50, 52 may be formed separately from and attached to the absorbent substrate 11, or may be integrally formed with the substrate 11. In one embodiment, the leak-proof flaps 50, 52 may be fixed laterally inward from a leg opening to the substrate 11 of the absorbent articles 10, 210 in a generally parallel and spaced-apart relationship to provide a barrier against the flow of bodily fluids. One leak-proof flap 50 may be on a first side of the longitudinal axis 29, while the other leak-proof flap 52 may be on a second side of the longitudinal axis 29. In one embodiment, the leak-proof flaps 50, 52 may 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 rear waist region 14 of the absorbent article 10. In some embodiments, the leak-proof flaps 50, 52 may extend in a direction substantially parallel to the longitudinal axis 29 of the absorbent articles 10, 210; however, in other embodiments, the leak-proof flaps 50, 52 may be curved, as is known in the art. In other embodiments, such as in Figure 3 and Figure 4 In the absorbent product 210, leak-proof flaps 50 and 52 can be disposed on the absorbent sheet 17 in the crotch area 16.

[0073] In one embodiment where the leak-proof flaps 50, 52 are attached to the backing sheet 11, the leak-proof flaps 50, 52 can be bonded to the body side lining 28 using barrier adhesive 49, such as Figure 5 As shown in the diagram. Alternatively, the leak-proof flaps 50, 52 can be bonded to the outer cover 26 or to the spacer layer 48 using barrier adhesive 49. Of course, the leak-proof flaps 50, 52 can be bonded to other parts of the substrate 11, and can be bonded using other suitable methods besides barrier adhesive 49. The leak-proof flaps 50, 52 can be constructed of a fibrous material, which can be similar to the material forming the body side lining 28. Other conventional materials, such as polymer films, can also be used.

[0074] Leak-proof flaps 50, 52 may each include a base portion 64 and a protruding portion 66. The base portion 64 may be bonded to the substrate 11, for example, to the body-side liner 28 or the outer cover 26 as described above. The base portion 64 may include a proximal end 64a and a distal end 64b. The protruding portion 66 may separate from the base portion 64 at its proximal end 64a. As used in this context, the protruding portion 66 separates from the base portion 64 at its proximal end 64a because the proximal end 64a defines the transition between the protruding portion 66 and the base portion 64. The proximal end 64a of the base portion 64 may be located near the barrier adhesive 49. In some embodiments, the distal end 64b of the base portion 64 may extend laterally to the respective longitudinal side edges 18, 20 of the absorbent articles 10, 210. In other embodiments, the distal end 64b of the base portion 64 may laterally terminate inwardly at the respective longitudinal side edges 18, 20 of the absorbent articles 10, 210. The leak-proof flaps 50, 52 may each include a protrusion 66 configured to extend at least in the crotch area 16 away from the body-facing surface 19 of the backing 11 when the absorbent articles 10, 210 are in a relaxed configuration. Figure 5 As shown in the diagram. Leak-proof flaps 50, 52 may be included in the pinning area 71 of either or both of the front waist area 12 and the rear waist area 14, with the protrusion 66 here connecting to the body-facing surface 19 of the substrate 11.

[0075] It is conceivable that the leak-proof fins 50 and 52 can have various configurations and shapes, and can be constructed using various methods. For example, Figure 5 The leak-proof flaps 50, 52 are depicted as vertical leak-proof flaps 50, 52 having a stapling area 71 in both the front waist region 12 and the rear waist region 14, at which the protruding portion 66 of each leak-proof flap 50, 52 is stapled toward or away from the longitudinal axis 29 of the absorbent article 10, 210 into the body side liner 28. However, the leak-proof flaps 50, 52 may include a stapling area 71, at which the protruding portion 66 of each leak-proof flap 50, 52 folds back onto itself and joins itself and the body side liner 28 in a “C-shaped” configuration, as 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 conceivable that the leak-proof flaps 50, 52 may be constructed in a “T-shaped” configuration, as described in U.S. Patent No. 9,259,362 to Robert L. Popp et al. Such a configuration may also include a pinning area 71 in either or both of the front waist region 12 and the rear waist region 14. Of course, leak-proof flaps 50, 52 of other configurations may be used in absorbent articles 10, 210 and are still within the scope of this 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 to 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 to 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] Because the distal portion 78 of the waist leak-proof member 54 is freely movable relative to the absorbent assembly 44 when the absorbent articles 10, 210 are in a relaxed configuration, the distal portion 78 can help provide a leak-proof bag 82 when the absorbent articles 10, 210 are in a relaxed configuration. The leak-proof bag 82 can help provide a barrier to contain bodily excretions and / or can help absorb bodily excretions. The leak-proof bag 82 is particularly advantageous for containing and / or absorbing low-viscosity feces (which may be common in young children). The first longitudinal side edge 72 is laterally outwardly disposed from the proximal end 64a of the base portion 64 of the leak-proof flap 50, so that the leak-proof bag 82 can extend laterally outward from the proximal end 64a of the leak-proof flap 50. Similarly, the second longitudinal side edge 74 is laterally outwardly disposed from the proximal end 64a of the base portion 64 of the leak-proof flap 52, so that the leak-proof bag 82 can extend laterally outward from the proximal end 64a of the leak-proof flap 52. This configuration provides a waist leak-proof member 54 with a spacious leak-proof bag 82 to accommodate and / or absorb bodily fluids.

[0091] To help prevent lateral flow of bodily fluids contained in the leak-proof bag 82 of the waist leak-proof member 54, the distal portion 78 of the waist leak-proof member 54 can be bonded to the proximal portion of the waist leak-proof member 54 and / or the body-facing surface 19 of the backing sheet 11 near the first longitudinal side edge 72 and the second longitudinal side edge 74, respectively. For example, Figure 5 Pinning zones 84 are depicted where the distal portion 78 of the waist leak-proof member 54 can be bonded to the proximal portion of the waist leak-proof member 54 and / or the body-facing surface 19 of the backing 11.

[0092] In a preferred embodiment, the waist leak-proof member 54 may include at least one elastic member, and in a further embodiment, even more elastic members. Generally, the elastic member may extend substantially from the first longitudinal side edge 72 of the waist leak-proof member 54 to the second longitudinal side edge 74. The elastic member may be disposed in the distal portion 78 of the waist leak-proof member 54, and preferably is located near the free edge 88 of the distal portion 78 of the waist leak-proof member 54.

[0093] A wide variety of elastomeric materials can be used for the elastic components in the waistline leak-proof member 54. Suitable elastomeric materials may include sheets, strands, or strips of natural rubber, synthetic rubber, elastic foam, or thermoplastic elastomer materials (e.g., films). The elastomeric material may be stretched and fixed to the substrate forming the waistline leak-proof member 54, fixed to a corrugated substrate, or fixed to the substrate and then elasticized or contracted, for example by applying heat, such that an elastic recoil force is imparted to the substrate forming the waistline leak-proof member 54.

[0094] The waist leak-proof member 54 can be configured to be attached to the backing sheet 11 by being positioned above or below the leak-proof flaps 50, 52. More specifically, the waist leak-proof member 54 can be disposed on the body-facing surface 19 of the backing sheet 11 such that the proximal portion of the waist leak-proof member 54 is positioned above the respective base portions 64 of the first leak-proof flap 50 and the second leak-proof flap 52. Alternatively, the waist leak-proof member 54 can be disposed on the body-facing surface 19 of the backing sheet 11 such that the proximal portion of the waist leak-proof member 54 is positioned below the respective base portions 64 of the first leak-proof flap 50 and the second leak-proof flap 52. Both configurations provide the advantage of facilitating the effectiveness of the waist leak-proof member 54 in containing and / or absorbing bodily fluids.

[0095] When the proximal portion of the waist leak-proof member 54 is disposed above the base portion 64 of the leak-proof fins 50, 52, the leak-proof fins 50, 52 may have movable fin elastic regions 70. When the absorbent article 10 is in a stretched, flat configuration, these movable fin elastic regions longitudinally overlap with the distal portion 78 of the waist leak-proof member 54, such as... Figure 2 As shown. Alternatively, the pinning area 71 may not extend from the rear waist edge 24 to the free edge 88 of the distal portion 78 of the waist leak-proof member 54, such as... Figure 2 As shown in the image.

[0096] When the proximal portion of the waist leak-proof member 54 is positioned below the base portion 64 of the leak-proof flaps 50, 52, the stapling area 71 of the protrusion 66 of each of the leak-proof flaps 50, 52 may longitudinally overlap with the distal portion 78 of the waist leak-proof member 54. In some of these embodiments, the stapling area 71 of the protrusion 66 of each of the leak-proof flaps 50, 52 may extend to the free edge 88 of the waist leak-proof member 54 to further facilitate the containment of exudate within the leak-proof bag 82 created by the waist leak-proof 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 generally compressible, conformable, flexible, non-irritating to the wearer's skin, and capable of absorbing and retaining liquid bodily excretions. The absorbent body 34 can be made in a wide variety of sizes and shapes (e.g., rectangular, trapezoidal, T-shaped, I-shaped, hourglass-shaped, etc.) and made of a wide variety of materials. The size and absorbency of the absorbent body 34 should be matched to the body size of the intended wearer (infant to adult) and the liquid load imposed by the intended use of the absorbent articles 10, 210. The absorbent body 34 may have a length and width that are less than or equal to the length and width of the absorbent articles 10, 210.

[0103] In one embodiment, the absorbent body 34 may be composed of absorbent materials, such as fibrous absorbent materials and / or superabsorbent materials, binder materials, surfactants, selected hydrophobic and hydrophilic materials, pigments, detergents, odor control agents, and combinations thereof. In one embodiment, the absorbent body 34 may be a matrix of cellulose fibers and superabsorbent materials. In another embodiment, the absorbent material of the absorbent body 34 may consist only of superabsorbent materials. In one embodiment, the absorbent body 34 may be constructed of a single layer of material, or alternatively, it may be constructed of two or more layers of material.

[0104] When at least partially composed of fibrous material, various types of wettable, hydrophilic fibers can be used in the absorbent body 34. Examples of suitable fibers include: natural fibers; cellulose fibers; synthetic fibers composed of cellulose or cellulose derivatives, such as man-made fibers; inorganic fibers composed of inherently wettable materials, such as glass fibers; synthetic fibers made of inherently wettable thermoplastic polymers, such as specific polyester or polyamide fibers, or synthetic fibers composed of non-wettable thermoplastic polymers, such as polyolefin fibers that have been hydrophilized in a suitable manner. For example, fibers can be hydrophilized by treatment with surfactants, treatment with silica, treatment with a material having a suitable hydrophilic portion that is not easily removed from the fiber, or by coating non-wettable hydrophobic fibers with a hydrophilic polymer during or after fiber formation.

[0105] When at least part of the material is composed of superabsorbent materials, such superabsorbent materials can be selected from natural, synthetic, and modified natural polymers and materials. Superabsorbent materials can be inorganic materials such as silica gel or organic compounds such as cross-linked polymers.

[0106] If a spacer layer 48 is present, the absorbent body 34 may be disposed on the spacer layer 48 and superimposed on the outer cover layer 26. The spacer layer 48 may be bonded to the outer cover layer 26, for example, by adhesive. In some embodiments, the spacer layer 48 may be absent, and the absorbent body 34 may be in direct contact with and bonded directly to the outer cover layer 26. However, it should be understood that the absorbent body 34 may be in contact with the outer cover layer 26 but not bonded to it, and remains within the scope of this disclosure. In one embodiment, the outer cover layer 26 may be composed of a single layer, and the absorbent body 34 may be in contact with the single layer of the outer cover layer 26. In one embodiment, at least a portion of a layer such as, but not limited to, a fluid transfer layer 46 and / or a spacer layer 48 may be positioned between the absorbent body 34 and the outer cover layer 26, such as... Figure 5 As shown in the diagram, the absorbent body 34 may be bonded to the fluid transfer layer 46 and / or the spacer layer 48.

[0107] According to some aspects of this disclosure, the absorber body 34 or at least one component of the absorber body 34 may include the absorber structure 101, as per [reference to...]. Figures 9A to 9C and 10A to Figure 10B A more detailed description is provided. In some embodiments, the absorber structure 101 may be the absorber body 34, such as regarding... Figures 1 to 5 The absorbent body is shown. In other embodiments, the absorbent structure 101 may comprise only a portion of the absorbent body 34. For example, the absorbent structure 101 may be housed within the absorbent body 34 along with other materials, such as one or more fibrous web materials and / or additional absorbent materials. Such other materials, together with the absorbent structure 101 (which generally forms the absorbent body 34), can generally be identified as part of the absorbent body 34 by being contained beneath a fluid transfer layer 46, which, in various embodiments, may or may 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 may together constitute the absorbent system of articles 10, 210.

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

[0109] The absorption structure 101 according to this disclosure can be formed according to the process disclosed herein, such as... Figures 6 to 8 Processes 300 and 400 are detailed in the text. Such absorbent structures 101 can advantageously provide greater thinness, flexibility, superabsorbent material trapping, and padding integrity than absorbent structures formed through different processes and / or comprising different materials or different relative amounts of materials. Although Figures 1 to 5 The absorbent diaper articles 10 and 210 are described in detail, but it should be understood that the absorbent structure 101 of this disclosure can be used in any absorbent article, including but not limited to diapers, diaper pants, training pants, baby pants, swim trunks, feminine hygiene products (including but not limited to menstrual pads or menstrual pants), incontinence products and other adult care clothing, medical clothing, surgical pads and bandages, other personal care or health care clothing, etc.

[0110] Figure 6 This is an exemplary schematic diagram of the absorbent structure formation process 300. Process 300 may include unfolding a web material 303 and moving the web material 303 along a machine direction 330. In some exemplary embodiments, an adhesive applicator 305 may apply an adhesive 306 to the web material 303. The adhesive applicator 305 may apply the adhesive 306 pneumatically or by various coating methods (or any other suitable coating method) to the web material 303 in the form of dots, beads, swirls, or any other suitable pattern. However, it should be noted that the adhesive applicator 305 and the adhesive 306 may be optional and are not present in other embodiments. Therefore, in such embodiments, the adhesive 306 is not placed on the web material 303.

[0111] In either case, the web material 303 may continue to advance along 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 binders 308, 310 before being deposited onto the web material 303 (e.g., in the mixing zone 312) and is finally deposited onto the web material 303.

[0112] Superabsorbent material 317 flows out of hopper 313 and through chute 315 to the web material 303. Hopper 313 can be a bulk solids pump or feeder, configured to maintain a consistent flow of superabsorbent material 317 through absorbent material deposition station 302. The flow rate of superabsorbent material 317 out of hopper 313 can be adjusted so that hopper 313 can deliver different amounts of superabsorbent material 317, thereby producing superabsorbent material 317 with different basis weights in the finished absorbent structure 101. This basis weight difference of superabsorbent material 317 allows the formed absorbent structure 101 to be used for different absorbent end uses, such as for diapers, feminine hygiene products, adult care clothing, bandages, etc.

[0113] The inclined groove 315 has an inclined groove end 354 (e.g.) Figure 7As shown), the end of the inclined groove is oriented in the vertical direction 332, such that the superabsorbent material 317 (in) Figure 7 The superabsorbent material 317 (shown as a single particle 318) falls substantially vertically 332 off the chute 315. The superabsorbent material 317 can preferably be supplied by gravity through the absorbent material deposition station 302 without any aerodynamic force. As used herein, the vertical direction 332 is used to denote a direction perpendicular to the web material 303. The machine direction 330 can be defined as a direction parallel within the web material 303, and therefore can be perpendicular to the vertical direction 332. In embodiments where the web material 303 is oriented horizontally relative to gravity (e.g., perpendicular to the direction of gravity), the vertical direction 332 can be substantially aligned with gravity. However, in other embodiments, the vertical direction 332 can be at an angle relative to gravity; for example, an angle differing from gravity by up to 25 degrees may be suitable for the vertical direction 332. Thus, in such embodiments, the superabsorbent material 317 can fall toward the web material 303, the orientation of which includes components in both the vertical direction 332 and the machine direction 330 (or possibly opposite to the machine direction 330).

[0114] In addition, regardless of the orientation of the vertical direction 332 relative to gravity, the inclined groove 315 can be further oriented in a non-perpendicular manner relative to the web material 303. For example, the end of the inclined groove 354 can be oriented perpendicularly to the web material 303 (e.g., Figure 7 (as shown), or it can be oriented to form an angle greater than 0 degrees and less than 25 degrees relative to the direction perpendicular to the fiber web material 303.

[0115] Generally, the amount of superabsorbent material 317 supplied by the absorbent material deposition station 302 can be configured such that the absorbent structure 101 includes superabsorbent material 317 in amounts 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. The basis weight of such superabsorbent material 317 used in absorbent structure 101 may be particularly suitable for absorbent clothing and feminine hygiene products. However, further absorbent structures 101 that may be formed according to various aspects of this disclosure may 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] The chute opening 354 may have an opening width 356 in the machine direction 330 (e.g., measured at the point where the superabsorbent material 317 exits the chute 315). The opening width 356 may 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 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 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 between 14 mm and 20 mm is preferred.

[0117] The combination of these features (gravity feeding method and chute opening width 356) helps to produce a “sheet” or “flow” of superabsorbent material 317 flowing toward the web material 303. The specific width 356 helps ensure that the flow 319 of superabsorbent material 317 has sufficient width and / or density (especially at the points where adhesive 308 and / or 310 contact the flow 319), which allows the adhesive 308 and / or 310 to better penetrate the flow 319 and mix with the superabsorbent material 317. These configurations can help drive the beneficial performance of the resulting absorbent structure 101, as described in more detail below. In some further embodiments, an airflow or air curtain may be used to help shape the flow 319 and / or maintain the desired width and / or density of the flow. In such embodiments, the superabsorbent material 317 may be directed toward the web material 303 somewhat faster than by gravity alone, but such embodiments can be considered to still include a gravity supply system because the superabsorbent material 317 is not pneumatically or otherwise ejected from the chute end 354.

[0118] As the superabsorbent material 317 falls onto the web material 303, adhesive applicators 307 and / or 309 can spray adhesive 308 and / or 310 onto the falling superabsorbent material 317. The adhesive 308 and / or 310 are mixed 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 This is a close-up schematic diagram of the absorbent material deposition station 302, showing more details about the adhesive applicators 307 and / or 309, and the adhesives 308 and / or 310.

[0119] The amount of adhesive 308 and / or 310 applied by adhesive applicators 307 and / or 309 can typically be applied at an addition 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 additional 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 "additional" amount or percentage refers to the amount of material added such that the resulting weight of the material within the absorbent structure 101 has a desired relationship with the weight of the absorbent material within the absorbent structure 101. As an illustrative example, when the superabsorbent material 317 is set in the absorbent structure 101 at a basis weight of 500 gsm, and when adhesive 308 and / or 310 are applied at an addition rate of 5%, the resulting basis weight of adhesive 308 and / or 310 in the formed absorbent structure will be 25 gsm (5% of 500 gsm).

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

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

[0122] To allow sufficient time for the first adhesive 308 to mix with the flow 319 of the superabsorbent material 317 before the mixture of the first adhesive 308 and the superabsorbent material 317 is deposited onto the web material 303, the first adhesive 308 is typically positioned at a first contact point 361 from the web material 303, where the flow 319 is located. This distance 361 may 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 the case where the first adhesive 308 is sprayed in a diffused manner and contacts the flow 319 along a length 363, the first contact point is measured relative to the center of the first adhesive 308 along the length 363 of its contact flow 319, and thus the distance 361 is measured.

[0123] To achieve this 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 and 351 can be adjusted to achieve the desired distance 361. As some non-limiting examples, the distance 355 is typically between 5 mm and 40 mm, or between 10 mm and 30 mm. By 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. A distance 359 greater than 70 mm, or 80 mm, or 90 mm may result in undesirable diffusion of the flow 319. A distance less than 60 mm or 50 mm may result in insufficient space between the chute 315 and the web material 303 to allow adequate mixing of the superabsorbent material 317 and the first adhesive 308 (or the second adhesive 310, described in more detail below).

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

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

[0126] To allow sufficient time for the second adhesive 310 to mix with the flow 319 of the 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 is typically in contact with the flow 319 at a second contact point located at a distance from the web material 303 equal to the sum of distance 367 and distance 361. The sum of distance 367 and distance 361 is typically 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. Furthermore, when the second adhesive 310 is sprayed in a diffuse manner and contacts the flow 319 along a length 365, the second contact point and the sum of distance 367 and distance 361 are measured relative to the center of the length 365 along which the second adhesive 310 contacts the flow 319 (if the first adhesive 308 contacts the flow 319 for a considerable length 363, it is measured relative to the center of the length 363).

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

[0128] It has been found that spraying adhesive 308 and / or 310 onto flow 319 may cause flow 319 to bend in the spraying direction. Without being bound by theory, it is believed that the forces of the adhesive 308 and / or 310 contacting the flow and / or the optional pattern of the air supplied by applicators 307 and / or 309 can cause this bending of flow 319. Therefore, where the first contact point of the first adhesive 308 with flow 319 is located at a lower point than the second contact point of the second adhesive 310 with flow 319, flow 319 may bend in machine 330 before being deposited onto the web material 303. This curvature of the flow 309 in the machine direction 330 helps ensure a smooth deposition of the mixture of superabsorbent material 317 and first binder 308 (and optionally second binder 310), resulting in a more uniform mixture 320, which has many benefits in terms of the capture and stabilization of superabsorbent material 317, the integrity of the resulting absorbent structure 101, and the uniform distribution of superabsorbent material 317 and first binder 308 (and optionally second binder 310).

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

[0130] Applicators 307 and / or 309 may preferably be configured to spray adhesives 308 and / or 310 in a substantially random pattern. It has been found that more random, irregular, or unstable spray patterns can produce better results in terms of the performance of the absorbent structure 101, such as in the capture and stabilization of the superabsorbent material 317, the integrity of the resulting absorbent structure 101, and the uniformity of distribution of the superabsorbent material 317 and adhesives 308 and / or 310. One such exemplary spray pattern is available from Universal, a product of Nordson Corporation (headquartered at 28601 Clemens Road, Westlake, OH 44145 USA). TM Signature TM The pattern produced by the nozzle. However, in other embodiments, different adhesive spray patterns that are more regular and less random but still considered random may be sufficient to produce an absorbent structure 101 with the desired performance properties. It can be further envisioned that some non-random spray patterns may also be sufficient to produce an absorbent structure 101 with 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 the deposition of mixture 320, vacuum energy may optionally be applied to the web material 303. For example, the web material 303 may be supported by a forming surface (such as a forming strip or forming drum commonly found in the art). Vacuum energy can be applied to the forming surface such that air is drawn through the forming surface from the side where the web material 303 is located. Therefore, the web material 303, along with mixture 320, is attracted to the forming surface due to the applied vacuum energy as it falls toward the web material 303. Such vacuum energy can help control the diffusion of mixture 320 as it falls toward the web material 303, thereby contributing to the formation of a relatively more uniform absorption structure 101. It has been found that particularly high pressure differentials at the forming surface are preferred, exceeding and surpassing typical pressure differentials in the art. For example, it may be preferred that the vacuum energy generates a pressure differential greater than 0.25 m water column at the forming surface. In a further embodiment, this may be more preferred for even higher pressure differentials, such as greater than 0.35 m water column, or greater than 0.5 m water column, or greater than 0.65 m water column (e.g., measured at the forming surface).

[0134] The web material 324 may be further applied to the deposited mixture 320. In some embodiments, an adhesive applicator 325 may spray an adhesive 326 onto the web material 324 before the web material 324 is positioned onto the deposited mixture 320. However, it should be understood that the adhesive applicator 325 is merely optional and may be absent in some embodiments. When present, the applied adhesive 326 is operable to bind the web material 324 more tightly to the deposited mixture 320 and / or further fix the superabsorbent material 317 within the formed absorbent structure.

[0135] According to some aspects of this disclosure, the combination of web material 303, deposited mixture 320, and web material 324 can pass through one or more roll gap stations 327 to help compress these components together. Generally, the roll gap station 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 web material 303, deposited mixture 320, and web material 324. Such pressure helps to further bond the deposited mixture to the web materials 303, 324. Although not required in all embodiments, it may be preferred that the roll gap station 327 be positioned relatively close to the material deposition station 302 such that the adhesives 308 and / or 310 remain open as the combination of web material 303, deposited mixture 320, and web material 324 passes through the roll gap station 327.

[0136] Following one or more roll gap stations 327, the combination of web material 303, deposited mixture 320, and web material 324 can be passed to a cutting station 329, where the connected 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 in the manufacturing process for producing the various absorbent products described herein.

[0137] Figure 8 An exemplary schematic diagram of an alternative absorbent structure formation process 400 is depicted. Process 400 is similar to process 300, except 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 compared to 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 an absorbent structure 101 with the desired performance properties decreases. If the desired amount of deposited superabsorbent material 317 is too high, a single absorbent material deposition station 302 may not be able to form a mixture of superabsorbent material 317 and binder sufficient to immobilize the superabsorbent material 317 (especially at a desired low binder addition amount). For example, in such instances, the superabsorbent material trapping properties of such formed absorbent structure 101 may be lower than desired.

[0138] Conversely, by employing two absorbent material deposition stations 302a and 302b, it may be possible to sufficiently fix the same desired amount of deposited superabsorbent material 317, resulting in an absorbent structure 101 with the desired superabsorbent material capture value. Furthermore, employing two absorbent material deposition stations 302a and 302b can improve productivity, even with lower amounts of superabsorbent material 317 and higher amounts of binder added. Therefore, in process 400, the mixture of superabsorbent material 317 and binder 308 and / or 310 is deposited at absorbent material deposition station 302a (which can be equivalent to...). Figure 6 and Figure 7 After the absorbent material deposition station 302 deposits the superabsorbent material 317 and the binder 308 and / or 310 onto the fiber web material 303, the fiber web material 303 and the mixture of deposited superabsorbent material 317 and binder 308 and / or 310 move onto the absorbent material deposition station 302b.

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

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

[0141] Generally speaking, regarding Figure 7 The location, position, distance, and other features, as well as optional components or features, of the described absorbent material deposition station 302 may be the same as those of absorbent material deposition station 302a. Similarly, absorbent material deposition station 302b may be the same as or substantially similar to absorbent material deposition station 302a. Absorbent material deposition station 302b may be located between 0.25m and 3.0m, or more preferably between 0.25m and 2.0m, or even more preferably between 0.25m and 1.0m.

[0142] Returning to fiber web materials 303 and 324, such 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 to 9C Different cross-sections of an exemplary absorbing structure 101 according to various aspects of this disclosure are depicted. (Representation) Figures 9A to 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 to 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 a Frazier Instruments LP air permeability tester (located in the office in Haggstown, Maryland), a Textest FX 3300 air permeability unit (located in the office in Schwezenbach, Switzerland), or an equivalent test unit.

[0152] Similarly, when the web material 303 forms the top surface 362 of the absorbent structure 101 and is positioned closest to the body-facing surface 19, the fibers of the web material 303, or at least the surface fibers, preferably possess sufficient wettability to allow fluid absorption, fluid flow, and fluid distribution through the web material 303 to the superabsorbent material 317. In some embodiments, wettability may arise from the composition of the fibers. For example, the fibers forming the web material 303 may be inherently wettable fibers, including natural cellulose fibers such as those from cotton, wood, or other fibers. Other examples of inherently wettable fibers include reconstituted cellulose fibers, such as synthetic fibers. In a further embodiment, the fibers forming the web material 303 may not be inherently wettable but may be modified to be wettable, such as by treating the fibers or at least the surface fibers with a surfactant. The surfactant treatment may be applied to at least the surface fibers in a continuous or discontinuous manner. In other embodiments, a surfactant treatment agent may be incorporated into the fibers, which will eventually migrate to the fiber surface.

[0153] When the web material 324 forms the bottom side 364 of the absorbent structure 101 and is located closest to the body-facing surface 19, the web material 324 can be any suitable nonwoven material, such as any material described with respect to web material 303. Furthermore, the web material 324 may preferably have any properties identical to those of the web material 303 described above. When 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 material described above with respect to web material 303, including any properties and their described ranges.

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

[0155] Generally, adhesive applicators 307 and / or 309 operate to spray adhesive 308 and / or 310, such that adhesive 308 and / or 310 form adhesive filaments 316 in contact flow 319. Adhesive applicators 307 and / or 309 are typically configured to spray adhesive 308 and / or 310, such that adhesive 308 and / or 310 form filaments 316 having a preferred diameter. It has been found that, possibly preferably, the diameter of the filaments 316 is between 25 micrometers and 150 micrometers, or between 50 micrometers and 100 micrometers, or between 75 micrometers and 100 micrometers. These ranges of filament diameters have shown good performance with superabsorbent material 317 having the following particle diameter to provide beneficial performance characteristics to structure 101.

[0156] Although the adhesive properties described above have been described with respect to adhesives 308 and / or 310, if adhesives 334 and / or 336 are present, adhesives 334 and / or 336 may have properties similar to those described above with respect to adhesives 308 and / or 310. Similarly, if applicators 333 and / or 335 are present, applicators 333 and / or 335 may be configured to spray adhesives 334 and / or 336 in a manner similar to how adhesive applicators 307 and / or 309 are configured to spray adhesives 308 and / or 310. For example, the diameter of the filament 316 formed from adhesives 334 and / or 336 sprayed from applicators 333 and / or 335 may be similar to the diameter described above with respect to the filament 316 formed from adhesives 308 and / or 310 sprayed from applicators 307 and / or 309.

[0157] In addition, it has been found that the size of the individual particles 318 of the superabsorbent material 317 can determine certain desired properties of the formed absorption structure 101. For example, the particle size of the individual particles 318 can at least partially determine the integrity of the pad and the capture value of the superabsorbent material, particularly in conjunction with the structural features of the binder filaments 316. For example, it has been found that good results are provided when the bulk superabsorbent material 317 has an average particle size with a diameter between 150 and 1000 micrometers, especially in conjunction with the diameter of the aforementioned binder filaments 316. In such embodiments, it may be preferred that at least 50% of the mass of the bulk superabsorbent material 317 has a diameter greater than 180 micrometers. In other embodiments, it may 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 micrometers. In a further embodiment, it may be more preferable that at least 50% of the mass of the bulk superabsorbent material 317 has a diameter greater than 300 micrometers, 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 micrometers.

[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 to 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 to 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 is (e.g., the basis weight of the superabsorbent material 317 in the central region 371 may be between 0% and 75% smaller than the basis weight of the superabsorbent material 317 in the side region 373).

[0164] 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 flows 319 and 331 may differ between the absorbent material deposition stations 302a and 302b. In some embodiments, the trans-machine direction width of flow 319 may be smaller than the trans-machine direction width of flow 319. In such embodiments, flow 319 may contribute superabsorbent material 317 substantially only within the central region 371. Therefore, in such embodiments, the trans-machine direction width of flow 331 may be greater than the trans-machine direction width of flow 319, contributing 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 flow 331 is smaller than the trans-machine direction width of flow 319. Such embodiments can produce an appearance substantially similar to Figure 10A The structure shown is 101.

[0165] In order to achieve Figure 10BIn the illustrated structure, one of flows 319, 331 may have a center (in the transverse machine direction 338) free of superabsorbent material 317. In such cases, one of flows 319, 331 may include two separate, spaced-apart sub-flows of superabsorbent material 317. In such embodiments, absorbent material deposition station 302a or 302b, which includes one of flows 319, 331, may contribute superabsorbent material 317 only to the side region 373, while the other absorbent material deposition station 302a or 302b provides superabsorbent material 317 to both the central region 371 and the side region 373. Of course, in different embodiments, it may be that either absorbent material deposition station 302a, 302b contributes superabsorbent material 317 only to the side region 373 of the absorbent structure 101. According to some embodiments, the adhesive applicators 307, 309, 333 and / or 335 (including stream 317 or 331, which is divided into two separate, spaced sub-streams) of the absorbent material deposition stations 302a, 302b can be configured to spray adhesive into the region between the two sub-streams of stream 319 or 317, such that the adhesives 308, 310, 334 and / or 336 used in process 400 are generally present in the central region 371 and side region 373 of the entire absorbent structure 101. Of course, in other embodiments, the adhesive applicators 307, 309, 333 and / or 335 (including stream 317 or 331, which is divided into two separate, spaced-apart sub-streams) of the absorbent material deposition stations 302a, 302b can be configured to spray adhesive only in the region of the sub-stream of stream 317 or 331, such that adhesives 308 and / or 310 or 334 and / or 336 may generally not be present in the central region 371 of the absorbent structure 101. Furthermore, it is possible that the basis weights of the side regions 373 may not be equal to each other. However, in most embodiments, the basis weights of the side regions 373 differ from each other by no more than 50%.

[0166] Figure 11A This is a perspective view of a computer-generated image 420 of the deposition mixture 320, based on a microscopic CT image obtained from an exemplary deposition mixture 320 formed by process 300. More specifically, it is used to illustrate... Figure 11AThe computer-generated mixture 420 shown is formed by process 300, wherein flow 319 and binders 308 and 310 are configured as listed in the first exemplary absorption structure detailed below, and the resulting structure 320 has a superabsorbent material 317 set in an amount of 400 gsm, and wherein binders 308, 310, 334 and 336 are present at an addition rate of 5%. The mixture 320 is stained with osmium tetroxide and then subjected to micro-CT scanning according to standard known staining and scanning techniques. As part of the micro-CT procedure, a portion of the stained and deposited mixture 320 is selected from approximately the center of the mixture 320 (e.g., structure 101) along both the width and length directions for imaging. This portion has a size of approximately 3 cm by 1 cm and is cut into approximately 1,250 individual segments extending along the transverse direction 392, each segment extending from end edge 395a to end edge 395b, and comprising 1,986 pixels in the longitudinal dimension (e.g., along the longitudinal direction 392). Each segment further comprises 504 pixels on a vertical direction 394 between the first surface 391 and the second surface 393. A voxel size of 8.0 micrometers is used. Based on the captured segments, a 3D model is generated and... Figures 11A to 11C It is depicted in the text.

[0167] When adhesives 308, 310, 334, and / or 336 are mixed with superabsorbent material 317, adhesive filaments 316 sprayed by applicators 307, 309, 311, and / or 313 cross and connect to form a three-dimensional mesh network 380. This three-dimensional mesh network has mesh adhesive filaments 381 extending substantially throughout the three-dimensional space formed by image 420, such as... Figure 11A and Figure 11B As can be seen in the image, the mesh adhesive filament 381 can be considered to extend substantially through the entire three-dimensional space formed by the deposition mixture in image 420, wherein the mesh adhesive filament 381 extends and mixes with the majority or super-major portion of the individual superabsorbent materials 317. This configuration contrasts with a configuration in which the adhesive filaments extend over the bags or groups of superabsorbent particles and do not extend into or between the individual superabsorbent materials 317 of the bags or groups of superabsorbent particles. The superabsorbent materials 317 are also disposed throughout the three-dimensional mesh network 380, shown as particles 318, and are held in place by contact with one or more mesh adhesive filaments 381.

[0168] Processes 300 and 400 are operable to mix adhesives 308, 310, 334, and / or 336 with superabsorbent material 317 to such an extent that the mesh adhesive filaments 381 contact substantially all of the individual superabsorbent materials 317. The mesh adhesive filaments 381 may be wound around most or most of the individual superabsorbent materials 317. As used herein, the mesh adhesive filaments 381 are considered to be wound around the individual superabsorbent particles 318 if the combined length of the individual mesh adhesive filaments 381 in contact with the individual superabsorbent particles 318 is equal to at least 40% of the maximum circumference of the individual superabsorbent particles 318.

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

[0170] The mesh adhesive filaments 381 of the three-dimensional mesh network 380 may further include vertically extending filaments 387, which can... Figure 11C Extend 394 in the vertical direction along the middle. Figure 11C express Figure 11A The image 420 is a transversely extended slice with a length of 0.5 mm in the longitudinal direction 392, which shows the interaction between the particles 318 and the adhesive filaments 381 in more detail. Figure 11D Is with Figure 11C The same image, with particles 318 removed, shows the adhesive filaments 381 and their arrangement along the vertical direction 394 in more detail.

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

[0172] exist Figures 11C to 11D Another feature that can be observed to some extent is the relative distribution of the network binder filaments 381 in different vertical zones of the deposited mixture, as shown in image 420. For example, as Figure 11C and Figure 11D As shown, image 420 can be divided into an outer region 396 and an inner region 398 disposed between the outer regions 396 and spanning a vertical direction 394. The outer regions 396 can each be defined by a thickness of 33% of the total thickness of structure 420, while the inner regions 398 can be defined by a thickness of 33% of the total thickness of structure 420.

[0173] It has been found that, ideally, processes 300 and / or 400 can penetrate adhesives 308, 310, 334, and / or 336 into the interior region 398, thereby promoting high SAM capture values ​​and greater pad uniformity through a more uniform distribution of superabsorbent material 317 and adhesives 308, 310, 334, and / or 336 throughout the structure 420. This is especially true when the basis weight of the superabsorbent material 317 in the molding mixture 320 of this 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 basis weight of the superabsorbent material 317 in the mixture 320 increases, it becomes more difficult for adhesives 308, 310, 334, and / or 336 to penetrate into the interior of flows 319 and / or 331, and processes 300 and / or 400 are superior compared to prior art processes.

[0174] To evaluate the ability of processes 300 and / or 400 to penetrate the adhesive into the internal region 398 of the molding mixture 320, analysis was performed on two sample codes. In the analysis, two sample codes were generated according to process 400, each having a superabsorbent material basis weight of 500 gsm and an adhesive set at an addition amount of 5%. Micro-CT images of portions of these two sample codes were formed from them according to the standard procedures and techniques described above. The adhesive distribution test method, described in detail below, was then performed on the generated micro-CT images to determine the relative amount of adhesive within the internal region 398 of the imaging portions of the two sample codes. The micro-CT images were generated using the known staining and imaging methods described above.

[0175] According to the adhesive distribution test method, it was found that the first sample code had 28.0% of the total adhesive content within the first sample code located in the inner region 398, with a standard deviation of 8.4%. The second sample code had 30.7% of the total adhesive content within the second sample code located in the inner region 398, with a standard deviation of 8.9%. Therefore, the mixture 320 formed according to processes 300 and / or 400 can result in a greater than 28% of the total adhesive content within the mixture 320 located in the inner region 398, or a greater than 30.5% of the total adhesive content within the mixture 320 located in the inner region 398. However, in a further potential embodiment, it is believed that by making slight modifications to processes 300 and / or 400, such as in the amount of adhesive added, vacuum energy, roll gap pressure, nozzle position and angle, it is possible to achieve a greater than 33%, or even greater than 35%, of the total adhesive content in the mixture 320 located in the inner region 398. This high binder penetration in the internal zone 398 of the molding mixture in processes 300 and / or 400 contributes to improved SAM capture, wet pad integrity, and pad uniformity results, as described in more detail below. The absorbent structure 101 produced by processes 300 and / or 400 has shown advantageous properties compared to prior art absorbent structures. For example, processes 300 and / or 400 have been shown to produce absorbent structure 101 that provides superior performance in the capture and fixation of the superabsorbent material 317, superior pad integrity of the formed absorbent structure 101, and more uniform distribution of the superabsorbent material 317 throughout the formed absorbent structure 101, as described in more detail below.

[0176] To compare absorption structures, a number of different absorption structures 101 were formed through processes 300 and / or 400 and tested relative to absorption structures formed by prior art processes. Exemplary absorption structures 101 and exemplary prior art absorption structures are compared with SAM capture testing methods, wet pad integrity testing methods, and pad uniformity testing methods, as described below, to produce comparison results.

[0177] First exemplary absorption structure

[0178] As described herein, a first exemplary absorbent structure 101 is formed according to exemplary process 300, the first exemplary absorbent structure being labeled as absorbent structures S23, S27, S53, and S57. Specifically, the first exemplary absorbent structure 101 formed according to exemplary process 300 has a basis weight of 200 gsm and a binder addition of 3% (labeled as structure S23), has a basis weight of 200 gsm and a binder addition of 7% (labeled as structure S27), has a basis weight of 500 gsm and a binder addition of 3% (labeled as structure S53), and has a basis weight of 500 gsm and a binder addition of 7% (labeled as structure S57).

[0179] The process 300 for forming the exemplary absorbent structures S23, S27, S53, and S57 includes the use of two adhesive applicators 307 and 309. Adhesive applicator 307 is positioned at a distance from the web material 303 and the flow 319, such that the adhesive contacts the flow 319 at a distance of 6.4 mm (e.g., distance 361) from the web material 303. Adhesive applicator 309 is positioned at a distance from the web material 303 and the flow 319, such that adhesive 310 contacts the flow 319 at a distance of 16 mm (e.g., distance 367 plus distance 361) from the web material 303. Additionally, a chute 315 is positioned at a distance of 76 mm (359) from the web material 303. Adhesive nozzle 321 is positioned at an angle 359a of 60 degrees relative to the machine direction 330, and adhesive nozzle 323 is also positioned at an angle 60 degrees relative to the machine direction 330. Nozzles 321 and 232 are available from Nordson Corporation's Universal TM Signature TM Nozzle. The chute width 356 is set to 12 mm, and the roll gap pressure at roll gap station 327 is 1 PLI (175.1 N / m). 8 gsm SMS material is used for material web materials 303 and 324. Vacuum energy is applied to create a pressure difference of approximately 0.51 m water column on the forming surface.

[0180] Second exemplary absorption structure

[0181] As described herein, a second exemplary absorbent structure 101 is formed according to an exemplary method 400, and this second exemplary absorbent structure is designated as absorbent structures D23-D67. Specifically, the second exemplary absorbent structure 101 formed according to the exemplary method 400 has a basis weight of 200 gsm and a binder addition of 3% (designated as structure D23), a basis weight of 200 gsm and a binder addition of 4% (designated as structure D24), a basis weight of 200 gsm and a binder addition of 5% (designated as structure D25), a basis weight of 200 gsm and a binder addition of 6% (designated as structure D26), and a basis weight of 200 gsm and a binder addition of 7% (designated as structure D27). A further second exemplary absorbent structure 101 is formed according to the exemplary method 400, the second exemplary absorbent structure having a basis weight of 300 gsm and an adhesive addition of 3% (labeled as structure D33), having a basis weight of 300 gsm and an adhesive addition of 4% (labeled as structure D34), having a basis weight of 300 gsm and an adhesive addition of 5% (labeled as structure D35), having a basis weight of 300 gsm and an adhesive addition of 6% (labeled as structure D36), and having a basis weight of 300 gsm and an adhesive addition of 7% (labeled as structure D37). Further second exemplary absorbent structures 101 are formed according to exemplary method 400, the second exemplary absorbent structures having a basis weight of 400 gsm and a binder addition of 3% (labeled structure D43), having a basis weight of 400 gsm and a binder addition of 4% (labeled structure D44), having a basis weight of 400 gsm and a binder addition of 5% (labeled structure D45), having a basis weight of 400 gsm and a binder addition of 6% (labeled structure D46), and having a basis weight of 400 gsm and a binder addition of 7% (labeled structure D47).According to exemplary method 400, even more second exemplary absorbent structures 101 are formed, the second exemplary absorbent structures having a basis weight of 500 gsm and a binder addition of 3% (labeled structure D53), having a basis weight of 500 gsm and a binder addition of 4% (labeled structure D54), having a basis weight of 500 gsm and a binder addition of 5% (labeled structure D55), having a basis weight of 500 gsm and a binder addition of 6% (labeled structure D56), and having a basis weight of 500 gsm and a binder addition of 7% (labeled structure D57). Further... The second exemplary absorbent structure 101 has a basis weight of 600 gsm and an adhesive addition of 2% (labeled as structure D62), has a basis weight of 600 gsm and an adhesive addition of 3% (labeled as structure D63), has a basis weight of 600 gsm and an adhesive addition of 4% (labeled as structure D64), has a basis weight of 600 gsm and an adhesive addition of 5% (labeled as structure D65), has a basis weight of 600 gsm and an adhesive addition of 6% (labeled as structure D66), and has a basis weight of 600 gsm and an adhesive addition of 7% (labeled as structure D67).

[0182] The setup for process 400 for forming exemplary absorbent structures D23-D27, D33-D37, D43-D47, D53-D57, and D62-D67 includes the use of two adhesive applicators 307 and 309 within an absorbent material deposition station 302a. Adhesive applicator 307 is positioned at a distance from the web 303 and the flow 319 such that the adhesive contacts the flow 319 at a distance of 6.4 mm from the web 303 (e.g., distance 361). Adhesive applicator 309 is positioned at a distance from the web material 303 and the flow 319 such that adhesive 310 contacts the flow 319 at a distance of 16 mm from the web material 303 (e.g., distance 367 plus distance 361). Additionally, a chute 315 is positioned at a distance of 76 mm from the web material 303 at a distance of 359. Adhesive nozzle 321 is positioned at an angle 359a of 60 degrees relative to the machine direction 330, and 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 roll gap pressure at roll gap station 327 is 1 PLI (175.1 N / m). The setup of absorbent material deposition station 302b is substantially the same as that of absorbent material deposition station 302a. 8 gsm SMS is used for the material web materials 303 and 324, and vacuum energy is applied, resulting in a pressure difference of approximately 0.51 m water column on the forming surface.

[0183] Third exemplary absorption structure

[0184] As described herein, the third exemplary absorber structure 101 (marked as absorber structures N23-N67 (or more specifically, absorber structures N23-N27, N33-N37, N43-N47, N53-N57, and N62-N67)) is formed according to an exemplary prior art process of U.S. Patent No. 8,986,474 to Kufner et al., and is assigned to Nordson Corporation (hereinafter referred to as "Nordson" or "Nordson References"). The exemplary absorber structures N23-N67 are based on U.S. Patent No. 8,986,474. Figure 3 The Nordson process forms this, using a single absorbent material deposition station with two binder distribution units. Such distribution units (e.g., those in the Nordson references) Figure 3 Units 22 and 72 (shown) are configured such that the discharged adhesive streams 26 and 76 converge at the powder mixture 56 and are each oriented at a 45-degree angle. Both adhesive streams 26 and 76 are in contact with the powder mixture 56 at a distance of 12.7 mm from the web material. A chute similar to chute 315 is used and positioned at a distance of 76 mm from the web material, and is set to have a width of 12 mm (e.g., width 356 similar to chute 315 of this disclosure). Although not necessarily disclosed in Nordson's references, the absorbent structures formed according to the Nordson process undergo the same post-processing as described in methods 300 and 400, i.e., passing through a roll gap station (such as roll gap station 327) at a setting of 1 PLI (175.1 N / m), and are then cut into individual absorbent structures 101. Vacuum energy is applied such that the forming surface has a pressure difference of approximately 0.51 m water column. As with the first and second exemplary absorber structures, 8gsm SMS material is used for material web materials 303 and 324.

[0185] Using the existing Nordson process configured as described above, a number of absorbent structures were produced. Specifically, a third exemplary absorbent structure 101 was produced, which has a basis weight of 200 gsm and a binder addition of 3% (labeled as structure N23), a basis weight of 200 gsm and a binder addition of 4% (labeled as structure N24), a basis weight of 200 gsm and a binder addition of 5% (labeled as structure N25), a basis weight of 200 gsm and a binder addition of 6% (labeled as structure N26), and a basis weight of 200 gsm and a binder addition of 7% (labeled as structure N27). According to the example The Nordson process forms further third exemplary absorbent structures having a basis weight of 300 gsm and a binder addition of 3% (labeled as structure N33), having a basis weight of 300 gsm and a binder addition of 4% (labeled as structure N34), having a basis weight of 300 gsm and a binder addition of 5% (labeled as structure N35), having a basis weight of 300 gsm and a binder addition of 6% (labeled as structure N36), and having a basis weight of 300 gsm and a binder addition of 7% (labeled as structure N37). Further third exemplary absorbent structures are formed according to the Nordson process, the third exemplary absorbent structures having a basis weight of 400 gsm and a binder addition of 3% (labeled as structure N43), having a basis weight of 400 gsm and a binder addition of 4% (labeled as structure N44), having a basis weight of 400 gsm and a binder addition of 5% (labeled as structure N45), having a basis weight of 400 gsm and a binder addition of 6% (labeled as structure N46), and having a basis weight of 400 gsm and a binder addition of 7% (labeled as structure N47).According to the Nordson process, even more third exemplary absorbent structures are formed, having a basis weight of 500 gsm and a binder addition of 3% (labeled structure N53), a basis weight of 500 gsm and a binder addition of 4% (labeled structure N54), a basis weight of 500 gsm and a binder addition of 5% (labeled structure N55), a basis weight of 500 gsm and a binder addition of 6% (labeled structure N56), and a basis weight of 500 gsm and a binder addition of 7% (labeled structure N57). Further third exemplary structures are formed. Absorbing structure 101, the third exemplary absorbing structure having a basis weight of 600 gsm and a binder addition of 2% (labeled as structure N62), having a basis weight of 600 gsm and a binder addition of 3% (labeled as structure N63), having a basis weight of 600 gsm and a binder addition of 4% (labeled as structure N64), having a basis weight of 600 gsm and a binder addition of 5% (labeled as structure N65), having a basis weight of 600 gsm and a binder addition of 6% (labeled as structure N66), and having a basis weight of 600 gsm and a binder addition of 7% (labeled as structure N67).

[0186] SAM capture test method results

[0187] Absorbing structures 101 (labeled as S23, S27, S53, and S57), D23-D27, D33-D37, D43-D47, D53-D57, and D62-D67, and N23-N27, N33-N37, N43-N47, N53-N57, and N62-N67, were all tested according to the SAM capture test method described in more 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 indicate the process settings used to form the corresponding structures. For example, the SAM gsm column indicates that the process is set up to produce an absorbent structure 101 with an average basis weight of 200 gsm of superabsorbent particles 17. The %Adh column indicates that the process is set up to produce an absorbent structure 101 having an average basis weight of a combination of one or more adhesives used as a specified weight percentage of the weight of the superabsorbent particles 17 in structure 101. As a specific example, when the SAM gsm column indicates 200 gsm and the %Adh column indicates 3%, the specified absorbent structure 101 is formed such that the basis weight of the adhesive is 3% of the 200 gsm of superabsorbent particles 17 set throughout structure 101, i.e., 6 gsm. The average %SAM capture value is a measure of the percentage of superabsorbent material 317 retained by a specific 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]

[0214] Table 1L

[0215] Therefore, there are significant performance differences between some codes formed according to various aspects of this disclosure and codes generated by the Nordson process (particularly codes with relatively low %Adh values). Specifically, it can be seen that the absorber structure 101 with a basis weight of superabsorbent particles 17 produced according to various aspects of this disclosure, with a basis weight between 400 gsm and 600 gsm and a %Adh value between 4% and 5%, has a %SAM capture value greater than 98.0, which is higher than any code of absorber structure produced by the Nordson process (code N45, falling within the specified range of SAM gsm and %Adh, with the highest %SAM capture value of 97.9). Alternatively, the structure 101 with a basis weight of superabsorbent particles 17 formed according to various aspects of this disclosure, with a basis weight between 400 gsm and 600 gsm and a %Adh value between 4% and 5%, can be described as having a %SAM capture value greater than 98.5.

[0216] Furthermore, many codes generated according to various aspects of this disclosure have %SAM capture values ​​greater than 98.0, such as codes D65 (%SAM capture value 98.1), D64 (%SAM capture value 98.3), D55 (%SAM capture value 99.5), D54 (%SAM capture value 99.3), D45 (%SAM capture value 99.8), and D44 (%SAM capture value 99.3). Many corresponding codes for the absorption structure produced according to the Nordson process (e.g., codes with corresponding SAM gsm and %Adh values) have much lower %SAM capture values; for example, N65 has a %SAM capture value of 87.0, N64 has a %SAM capture value of 88.8, and N44 has a %SAM capture value of 97.3.

[0217] Further emphasizing the codes with basis weights between 500 gsm and 600 gsm and %Adh values ​​between 4% and 5%, the absorber structures 101 formed according to various aspects of this disclosure all have %SAM capture values ​​greater than 96.5. For example, the %SAM capture values ​​of codes D54, D55, D64, and D65 are 99.3, 99.5, 98.3, and 98.1, respectively. The corresponding %SAM capture values ​​of codes N54, N55, N64, and N65 are 94.8, 96.2, 88.8, and 87.0, respectively.

[0218] When 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 performance advantage of the code of structure 101 formed according to various aspects of this disclosure compared to the code of absorber structures produced by the Nordson process may also be apparent. In such instances, structures 101 produced according to various aspects of this disclosure all have %SAM capture values ​​greater than 95.0, which is higher than any code of absorber structures produced by the Nordson process (code N54, falling within the specified range of SAM gsm and %Adh, has the highest %SAM capture value of 94.8).

[0219] Furthermore, many codes generated according to various aspects of this disclosure have %SAM capture values ​​greater than 95.0, such as codes D53 (%SAM capture value 97.2), D54 (%SAM capture value 99.3), D63 (%SAM capture value 95.6), and D64 (%SAM capture value 98.3). Many corresponding codes for absorption structures produced according to the Nordson process have much lower %SAM capture values; for example, N53 has a %SAM capture value of 92.8, N63 has a %SAM capture value of 88.1, and N64 has a %SAM capture value of 88.8.

[0220] With %Adh values ​​increasing to between 4% and 5%, structures 101 of the superabsorbent particles 17 produced according to various aspects of this disclosure, with basis weights between 500 gsm and 600 gsm, still outperform the absorber structures produced by the Nordson process because all structures have %SAM capture values ​​greater than 97.0. For example, the %SAM capture values ​​for codes D54, D55, D64, and D65 are 99.3, 99.5, 98.3, and 98.1, respectively. The %SAM capture values ​​for the corresponding absorber structures (codes N54, N55, N64, and N65) produced by the Nordson process are 94.8, 96.2, 88.8, and 87.0, respectively.

[0221] Even when the %Adh value increases to between 5% and 6%, structures 101 produced according to various aspects of this disclosure with superabsorbent particles 17 having a basis weight between 500 gsm and 600 gsm are still superior to absorber structures produced by the Nordson process because all structures have a %SAM capture value greater than 97.0. For example, the %SAM capture values ​​of codes D55, D56, D65, and D66 are 99.5, 99.8, 98.1, and 98.9, respectively. The %SAM capture values ​​of the corresponding absorber structures (codes N55, N56, N65, and N66) produced by the Nordson process are 96.2, 96.7, 87.0, and 85.6, respectively.

[0222] Results of wet mat integrity test method

[0223] In comparative measurements of the absorber structure 101 formed according to various aspects of this disclosure and the absorber structure formed according to the Nordson process, numerous different codes were generated. As shown in Table 2A below, absorber structures 101 formed according to various aspects of this disclosure were produced and labeled as codes DD23, DD27, DD53, and DD57. Codes DD23, DD27, DD53, and DD57 were formed through a process similar to that described above with respect to the second exemplary absorber structure. In addition, corresponding absorber structures were formed according to the Nordson process, as shown in Table 2B and labeled as NN23, NN27, NN53, and NN57. Codes NN23, NN27, NN53, and NN57 were formed through a process similar to that described above with respect to the third exemplary absorber structure. Five of each of these codes were tested according to the wet pad integrity test method described in more detail below, and the results are shown in Tables 2A and 2B below. The Avg# column details the average number of shakes (average of five samples tested) imparted to the structure during the wet pad integrity test method, with a maximum of 50 shakes to maintain the structure's integrity.

[0224]

[0225] Table 2A

[0226]

[0227] Table 2B

[0228] As can be seen from Tables 2A and 2B, the absorbent structure 101 formed according to various aspects of this disclosure has a significant advantage in terms of wet pad integrity compared to the absorbent structure formed according to the Nordson process. For example, code DD57 (representing absorbent structure 101 formed as a combination of an average basis weight of 500 gsm superabsorbent material 317 and a basis weight of one or more adhesives accounting for 7% of the basis weight of the superabsorbent material 317) has a wet pad integrity value of 38, which is 110% higher than the wet pad integrity value of the corresponding code NN57 formed according to the Nordson process (NN57 has a wet pad integrity value of 18). In other embodiments, when such absorbent structure 101 is formed as a combination of an average basis weight of 500 gsm superabsorbent material 317 and a basis weight of one or more adhesives accounting for 7% of the basis weight of the superabsorbent material 317, the absorbent structure 101 formed according to various aspects of this disclosure can be described as having a wet pad integrity value of at least 25, or at least 30, or at least 35. As another example, code DD53 (representing absorbent structure 101, which is formed as an average basis weight of superabsorbent material 317 with 500 gsm and a combined basis weight of one or more adhesives accounting for 3% of the basis weight of superabsorbent material 317) has a wet pad integrity value of 3, which is higher than the wet pad integrity value of the corresponding code NN53 formed according to the Nordson process (NN53 has a wet pad integrity of 0), which cannot even withstand a single shake from the wet pad integrity test method.

[0229] In this way, it can be seen that the absorbent structure 101 produced by processes 300 and 400 has better wet pad 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 to form a superabsorbent material stream, and further include spraying an adhesive onto a first and second side of the stream. As described herein, the adhesive is mixed with the superabsorbent material 317 before being deposited onto the web material 303. Therefore, based on the above results, according to wet pad integrity tests, these processes are additionally capable of producing absorbent structures 101 with a wet pad integrity value greater than or equal to 20, at least when used to produce structures 101 having superabsorbent material 317 set in an amount equal to 500 gsm and an adhesive set 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 is possible that the process includes feeding two separate streams of superabsorbent material 317 toward the web material 303 and spraying an adhesive onto the first and second sides of these two streams of superabsorbent material 317. Furthermore, when such an absorbent structure 101 is formed having an average basis weight of 500 gsm of superabsorbent material 317 and a combined basis weight of one or more adhesives accounting for 7% of the basis weight of the superabsorbent material 317, such a process according to the present disclosure can be described as capable of forming an absorbent structure 101 having a wet pad integrity value of at least 25, or at least 30, or at least 35. Additionally, when such an absorbent structure 101 is formed having an average basis weight of 500 gsm of superabsorbent material 317 and a combined basis weight of one or more adhesives accounting for 3% of the basis weight of the superabsorbent material 317, such a process according to the present disclosure can form an absorbent structure 101 having a wet pad integrity value of at least 1, or at least 2, or at least 3.

[0230] Results of Pad Uniformity Test Method

[0231] Another feature of the method described herein, compared to the Nordson process, is that the process described herein is able to produce an absorber structure 101 with a more uniform distribution of superabsorbent material 317 and adhesive fibers 316 throughout the formed structure 101, compared to absorber structures formed according to the Nordson process. This higher uniformity allows the absorber structure 101 to be thinner, more flexible, and better at handling fluids compared to absorber structures with similar basis weights of superabsorbent material and adhesives.

[0232] To compare the distribution of the superabsorbent material 317 and the adhesive fiber 316, a number of different absorption structures 101 were formed according to various aspects of this disclosure and compared with a number of different absorption structures formed according to the Nordson process. As can be seen from Tables 3A-3E, the absorption structures 101 formed according to various aspects of this disclosure are labeled with codes DDD23, DDD24, DDD27, DDD33, DDD34, DDD44, DDD45, DDD56, DDD62, DDD66, and DDD67. These codes are formed through a process similar to that described above with respect to the second exemplary absorption structure. The absorption structures formed according to the Nordson process are labeled with NNN23, NNN24, NNN27, NNN33, NNN34, NNN44, NNN45, NNN56, NNN62, NNN66, and NNN67. These codes are formed through a process similar to that described above with respect to the third exemplary absorption structure.

[0233] Tables 3A-3E report the results for various codes according to the pad uniformity test method, representing the results for a single sample for each code. The CD GL Var. column details the gray level variation over a portion of the sample along the lateral extension, as determined by the pad uniformity test method. Lower gray level variance values ​​generally indicate a more uniform structure because the variance of the determined gray levels is lower. The CD Mean GL column reports the average gray level value of the sample as determined by the pad uniformity test method, while the GL%COV value reports the calculated gray level variability relative to the average gray level. For example, for a given sample, the GL%COV value is determined by dividing the standard deviation of the gray levels by the average gray level and multiplying such a calculated value by 100%.

[0234] The determination of all these values ​​is described in more detail below regarding the pad uniformity test method.

[0235]

[0236] Table 3A

[0237]

[0238] Table 3B

[0239]

[0240] Table 3C

[0241]

[0242] Table 3D

[0243]

[0244]

[0245] Table 3E

[0246] As can be seen from Tables 3A-3E, structure 101 produced by the process described herein produces a much lower grayscale variation than the absorber structure formed according to the Nordson process. For example, codes DDD23 and DDD24 have CD GL Var. values ​​less than 815, less than 800, less than 750, or less than 700, as determined by the pad uniformity test method. Such CD GL Var. values ​​are all less than the CD GL Var. values ​​of the corresponding codes NNN23 and NNN24. In other words, absorber structure 101 formed according to aspects of this disclosure (which has a superabsorbent material 317 set at a basis weight of 200 gsm and one or more adhesives set at a combined basis weight of less than 4 wt% of the basis weight of the superabsorbent material 317) may have CD GL Var. values ​​less than 815, less than 800, less than 750, or less than 700, as determined by the pad uniformity test method. In some of these embodiments, one or more adhesives may be set at a combined basis weight of 3 wt% to 4 wt% of the basis weight of the superabsorbent material 317.

[0247] Further examples show that codes DDD33 and DDD34 have CD GL Var. values ​​less than 675, less than 650, or less than 625, as determined by the pad uniformity test method. These CD GL Var. values ​​are all less than the CD GL Var. values ​​of the corresponding NNN33 and NNN34 codes. In other words, the absorbent structure 101 formed according to various aspects of this disclosure (having a superabsorbent material 317 set at a basis weight of 300 gsm and one or more adhesives set at a combined basis weight less than 4 wt% of the basis weight of the superabsorbent material 317) may have CD GL Var. values ​​less than 675, less than 650, or less than 625, as determined by the pad uniformity test method. In some of these embodiments, one or more adhesives may be set at a combined basis weight of 3 wt% to 4 wt% of the basis weight of the superabsorbent material 317.

[0248] Further examples show that codes DDD44 and DDD45 have CD GL Var. values ​​less than 575, less than 550, less than 525, or less than 500, as determined by the pad uniformity test method. These CD GL Var. values ​​are all less than the CD GL Var. values ​​of the corresponding codes NNN44 and NNN45. In other words, the absorbent structure 101 formed according to various aspects of this disclosure (having a superabsorbent material 317 set at a basis weight of 400 gsm and one or more adhesives set at a combined basis weight less than 5% by weight of the superabsorbent material 317) may have CDGL Var. values ​​less than 585, less than 550, less than 525, or less than 500, as determined by the pad uniformity test method. In some of these embodiments, one or more adhesives may be set at a combined basis weight of 4% to 5% by weight of the superabsorbent material 317.

[0249] Further examples show that code DDD56 has CD GL Var. values ​​less than 500, 475, 450, or 425, as determined by the pad uniformity test method. These CD GL Var. values ​​are all less than the CD GL Var. values ​​of the corresponding NNN56 code. In other words, the absorbent structure 101 formed according to various aspects of this disclosure (having a superabsorbent material 317 set at a basis weight of 500 gsm and one or more adhesives set at a combined basis weight of 6% by weight of the superabsorbent material 317) may have CD GL Var. values ​​less than 500, 475, 450, or 425, as determined by the pad uniformity test method.

[0250] Table 3E emphasizes that, particularly at the high basis weight of the superabsorbent material 317, the absorption structure 101 formed according to various aspects of this disclosure is superior to the absorption structure formed according to the Nordson process. Codes DDD62, DDD63, and DDD67 have CD GL Var. values ​​less than 475, less than 450, less than 425, less than 400, or less than 375, as determined by the pad uniformity test method. Specifically, codes DDD66 and DDD67 have CD GL Var. values ​​less than 350, less than 325, or less than 300. These CD GL Var. values ​​are all less than the CD GL Var. values ​​of the corresponding codes NNN62, NNN66, and NNN67. In other words, the absorbent structure 101 formed according to various aspects of this disclosure (which has a superabsorbent material 317 set at a basis weight of 600 gsm and one or more adhesives set at a combined basis weight of less than 7 wt% of the basis weight of the superabsorbent material 317) may have a CD GL Var. value 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 may be set at a combined basis weight of 2 wt% to 7 wt% of the basis weight of the superabsorbent material 317. In a further example of these examples, where the basis weight of one or more adhesives is set between 6 wt% and 7 wt% of the basis weight of the superabsorbent material 317, such an absorbent structure 101 may have a CD GL Var. value of less than 350, less than 325, or less than 300.

[0251] Additional features of the absorber structure 101 formed according to various aspects of this disclosure may include the following: The absorber structure 101, with a basis weight of superabsorbent material 317 between 500 gsm and 600 gsm, may have a CD GL Var. value of less than 475, less than 450, or less than 425. In at least some of these embodiments, one or more adhesives present in such structure 101 may have a basis weight of less than 7%, less than 6%, between 6% and 7%, or a combination of 2% and 7%. The absorber structure 101, with a basis weight of superabsorbent material 317 between 400 gsm and 500 gsm, may 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, one or more adhesives present in such structure 101 may have a basis weight of less than 6%, less than 5%, or a combination of 4% and 6%. The superabsorbent material 317 with a basis weight between 300 gsm and 400 gsm, and the absorbent structure 101, may have a CD GL Var. value of less than 590 or less than 580. In at least some of these embodiments, one or more adhesives present in such structure 101 may have a basis weight of less than 5%, less than 4%, or a combination of 3% and 5%. The absorbent structure 101 (with the superabsorbent material 317 having a basis weight between 200 gsm and 300 gsm and the combination of one or more adhesives present in such structure 101 having a basis weight between 3% and 4%) may have a CD GL Var. value of less than 675, less than 665, or less than 655.

[0252] When using GL%COV values, it can be seen that the absorber structure 101 formed according to various aspects of this disclosure generally exhibits low variation in gray levels across different basis weights. For example, codes DDD44, DDD45, DDD56, DDD62, DDD66, and DDD67 all have GL%COV values ​​less than 34.5, less than 34, or less than 33.5. Such GL%COV values ​​are all less than the GL%COV values ​​of the corresponding codes NNN44, NNN45, NNN56, NNN62, NNN66, and NNN67. In other words, the absorber structure 101 formed according to various aspects of this disclosure (which has one or more adhesives set at a combined basis weight of superabsorbent material 317 at a basis weight between 400 gsm and 600 gsm and at a combined basis weight less than 7% by weight of the superabsorbent material 317) may have GL%COV values ​​less than 34.5, less than 34, or less than 33.5, as determined by the pad uniformity test method. In some of these embodiments, one or more adhesives may be set at a basis weight of superabsorbent material 317 between 4% and 7%, or in a combination of 4% and 6%. In a further embodiment of any of these embodiments, superabsorbent material 317 may be set at a basis weight between 400 gsm and 500 gsm.

[0253] As another example, codes DDD34, DDD44, and DDD45 all have GL%COV values ​​less than 31.5 or less than 31.3. The lowest GL%COV value corresponding to codes NNN34, NNN44, and NNN45 is 31.6. In other words, the absorbent structure 101 formed according to various aspects of this disclosure (which has one or more adhesives set at a basis weight of superabsorbent material 317 between 300 gsm and 400 gsm and at a combined basis weight between 4% and 5% by weight of the superabsorbent particles 318) may have GL%COV values ​​less than 31.5 or less than 31.3, as determined according to the pad uniformity test method.

[0254] SAM capture test method

[0255] First, obtain a separate sample absorbent structure, either by deconstructing a commercially available product or by obtaining a separate structure directly from the production line before incorporation into the product. If obtained from a commercially available product, the absorbent structure should be obtained using typical product deconstruction methods, such as using: cryo-spray or other equivalent products that help deactivate any adhesives laminating the layers of the product together, thus allowing for easier separation of the layers; and / or scissors to cut one or more sections of the product. If obtained directly from the production line, the sample absorbent structure should be cured for at least 24 hours.

[0256] Once the sample absorption structures are ready, each individual sample should be weighed and the weight recorded. Next, preferably, each sample structure is peeled off onto a trash can or similar object to capture any detached material. The sample can be peeled off by grasping an outer mesh material with each hand at one end of the structure and pulling it apart with a peeling motion. Once pulled apart, the separated meshes are gently shaken on a trash can and then placed back on the scale for a second weighing, which is then recorded.

[0257] The difference between the first recorded weight 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 superabsorbent material retained. In this disclosure, since the basis weight of the web material, the deposited superabsorbent material, and the amount of binder added are identical for the sample structures being compared, this difference is simply divided by the first recorded weight of the sample to obtain the reported percentage of superabsorbent material retention. However, when comparing different samples, the basis weight and size of the web material can be taken into account, for example, by subtracting the total weight of the sample web material from the first and second recorded weights. The total weight of the binder is generally negligible for determining the percentage of retention and is therefore not considered separately.

[0258] Wet pad integrity test method

[0259] First, obtain a separate sample absorbent structure, either by deconstructing a commercially available product or by obtaining a separate structure directly from the production line before incorporation into the product. If obtained from a commercially available product, the absorbent structure should be obtained using typical product deconstruction methods, such as using: cryo-spray or other equivalent products that help deactivate any adhesives laminating the layers of the product together, thus allowing for easier separation of the layers; and / or scissors to cut one or more sections of the product. If obtained directly from the production line, the sample absorbent structure should be cured for at least 24 hours.

[0260] Once obtained, mark the target location for each sample. The target location is marked 8.5 cm from the front edge of the sample. If the sample is removed from the 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 front of the product. The product should then be adhered to the lightbox or other suitable working surface. Double-sided tape or similar material positioned at the front and / or rear edges of the sample can be used to adhere the sample.

[0261] Next, center a 152mm long, 51mm diameter plastic tube (3.5mm wall thickness, 44mm inner diameter) at the target location. Place a plastic funnel on top of the tube and pour 100ml of 0.9% blue saline solution into the funnel. When securing the tube in place, avoid applying any pressure to the sample surface. Additionally, the funnel nozzle should be tilted towards the tube wall so that the saline solution flows down the wall before contacting the sample surface. After pouring the liquid into the funnel, set a 5-minute timer.

[0262] After 5 minutes, suspend the sample on the product shaker. The product shaker consists of a simple frame with a linear actuator attached to the top of the frame and oriented vertically. 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 front edge of the sample absorption structure is attached to the product shaker via 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 downward or one upward movement). A full-stroke movement is counted 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 psi and an actuation rate of approximately 30 mm per second may be particularly suitable. The linear actuator can be operated by extending and retracting cycles using any suitable and simple drive circuit. When the product shaker is turned on, observe the sample for any localized cracks, which constitute any cracks or gaps appearing in the sample. Once the first partial crack is observed, record the number of shakes and turn off the product shaker. If no localized cracks are observed after 50 shakes, stop the test and record the 50 shake values ​​for the sample.

[0263] Pad uniformity test method

[0264] The image analysis methods described herein can be used to determine the transverse machine direction (CD) grayscale variation properties of thin, lint-free absorbent webs, including structures 101 formed according to methods 300 and 400 of this disclosure and structures formed according to the Nordson process. In this case, the CD grayscale variation of the thin, lint-free absorbent web provides an indication of the uniformity of the distribution of binder and superabsorbent particles throughout the web. For example, a web with a lower CD grayscale variation can be considered to have binder and superabsorbent particles that are relatively more uniformly distributed throughout the web, because the amount of light passing through the web is relatively more uniform throughout the web compared to a web with a relatively higher CD grayscale variation, as will be explained in more detail below.

[0265] The method used to determine CD grayscale variations involves using diffused transmitted light that passes through a fiber optic mesh and is detected by the camera. Specifically, the camera can be a CCD camera, such as the Leica Microsystems DFC 310 camera available from Leica Microsystems in Helbrugge, Switzerland. The camera can be mounted to a large-lens viewfinder camera mount, such as a Polaroid MP4 large-lens viewfinder camera mount or equivalent. An adjustable lens assembly (such as a Nikon 35-mm lens with an aperture set to f / 4) is connected to the camera via a C-mount. The camera is set to monochrome mode, and flat field correction is performed on a white background prior to analysis.

[0266] An autostage, including a transparent support, is placed on the upper surface of the large-lens viewfinder, positioned between the camera and the diffused light source of the large-lens viewfinder. The autostage can be the HM-1212 model from a design component company or an equivalent. Diffuse illumination is provided by four LED tube lights (EMC-9 watts, dimmable) located below the autostage, and the large-lens viewfinder includes a diffuser plate positioned between the LED-lit autostage. The illuminance level of the LED lights can be controlled via a common voltage controller equipped with knobs or sliders for adjustment.

[0267] Two black masks are placed on a transparent support of the autostage, three inches apart, with elongated dimensions extending to the front and rear of the autostage (e.g., towards and away from the large-lens viewfinder camera mount). A mesh sample is laid flat on the transparent support, centered between the black masks, so that only the central area of ​​the sample is illuminated. The mesh sample is oriented similarly to the black masks, with its longitudinally extending side edges (e.g., the long side edges) facing towards and away from the camera mount. The camera and lens assembly is mounted on the large-lens viewfinder camera mount at a distance above the sample, which, across the width of the autostage (e.g., perpendicular to the longitudinally extending side edges of the sample), provides an image field of view of approximately 4.5 inches.

[0268] The fiber web samples were analyzed under the optical axis of the camera and lens assembly by placing them on the automated stage as described above. The samples must be laid flat, and care must be taken to eliminate or avoid wrinkles or similar deformations. An image analysis software package was used to monitor and adjust the illumination level, acquire images, and then perform measurements to determine grayscale changes. For the analysis, the Leica Microsystems LAS software platform and a custom-written algorithm, CD Change Grayscale Algorithm (ActivTech)-1, were used to monitor and adjust the illumination level for each sample and perform grayscale change measurements. The algorithm running using the LAS macro editor platform is shown below.

[0269] NAME = Gray level of CD change (Active Tech) - 1

[0270] Objective: To measure the grayscale values ​​of grid elements on a CD.

[0271] Conditions: DFC 310 camera; 35mm adjustable lens (f / 4); diffused transmitted light; rod = 76cm

[0272] Author = DG Biggs

[0273] Date = February 21, 2020

[0274] Open the data file and set variables

[0275] PauseText("Now enter the prefix names for the Excel data file and image file.") Enter (title$)

[0276] OPENFILE$="C:\Data\102888-Graverson\"+TITLE$+".xls"

[0277] Open file (OPENFILE$, channel #CHAN)

[0278] Set graphics variables

[0279] GRAPHNX=6

[0280] GRAPHNY = 2

[0281] GRAPHWID=790

[0282] GRAPHHGHT=118

[0283] GRAPHORGX = 270

[0284] GRAPHORGY = 100

[0285] GRAPHTHIK=2

[0286] GRAPHORNT=0

[0287] GRAPHOUT=0

[0288] Count = 0

[0289] Setup and Calibration

[0290] Calculated value = 0.0833 mm / px

[0291] Calculated value = 0.0833

[0292] Calibration (local)

[0293] Input result header

[0294] File Result Header (Channel #1)

[0295] File line (channel #1)

[0296] File line (channel #1)

[0297] Image frame (x 0, y 0, width 1392, height 1040)

[0298] Measurement frame (x 260, y 72, width 806, height 962)

[0299] Sample ring

[0300] For (samples = 1 to 3, step 1)

[0301] PauseText("Place the sample on the stage.")

[0302] Image settings DC Twain [Pause] (Camera 1, Auto Exposure Off, Gain 0.00, Exposure Time 15.69 ms, Brightness 0, Light 49.99)

[0303] Phase (definition origin)

[0304] Stage (scanned pattern, 1×3 field, size 102000.000000×96570.000000)

[0305] Image ring

[0306] For (images = 1 to 3, step 1)

[0307] Get Image

[0308] Image settings DC Twain [Pause] (Camera 1, Auto Exposure Off, Gain 0.00)

[0309] Exposure time 15.69 milliseconds, brightness 0, lamp size 49.99

[0310] Color Transformation (Monochrome Mode)

[0311] Get (enter image 0)

[0312] Count = Count + 1

[0313] --The next line indicates the image storage location on the hard drive.

[0314] ACQFILE$="C:\Images\102888-Graverson\"+TITLE$+"_"+STR$(COUNT)+".tif"

[0315] Write image (from ACQOUTPUT to file ACQFILE$)

[0316] GRAPHORGY = 100

[0317] Analysis loop

[0318] For (Analysis = 1 to 4, Step 1)

[0319] Binary processing

[0320] Graphics (inverted grid, GRAPHNX x GRAPHNY lines, grid size GRAPHWID x

[0321] GRAPHHGHT, origin GRAPHORGX x GRAPHORGY,

[0322] Thick GRAPHTHIK, orientation GRAPHONT, until GRAPHONT is removed)

[0323] Display(image0(on), frame(on, on), plane(0, off, off, off, off, off), lut0, x 0, y 0, z

[0324] Reduce shutdown)

[0325] Measuring feature gray level

[0326] Measurement features (planar binary 0, 32feet, minimum area: 4, grayscale image: image 0)

[0327] Selected parameters: X FCP, Y FCP, MeanGrey, GreyVarianc

[0328] File feature results (channel #1)

[0329] File line (channel #1)

[0330] File line (channel #1)

[0331] File line (channel #1)

[0332] Measure GL% COV

[0333] MGREYIMAGE=0

[0334] MGREYMASK=0

[0335] Measuring grayscale (planar MGREYIMAGE, mask MGREYMASK)

[0336] Histogram to GREYHIST(256), statistics to GREYSTATS(2))

[0337] Selected parameters: Mean Grey, Standard Deviation

[0338] MEANGREY=GREYSTATS(1)

[0339] GREYSDEV = GREYSTATS(2)

[0340] glpercov=greys dev / mean gray*100

[0341] File("GL%COV=", Channel l#1)

[0342] File(GLPERCCOV, channel #1, 2 digits after '.')

[0343] File line (channel #1)

[0344] File line (channel #1)

[0345] GRAPHORGY = GRAPHORGY + 250

[0346] Next step (analysis)

[0347] Phase (step, wait until stop + 550 milliseconds)

[0348] Next (image)

[0349] Next (sample)

[0350] Close file (channel #1)

[0351] Finish

[0352] After executing the algorithm using the Leica software, the system prompts the analyst to enter a prefix name for the EXCEL data file sample and image files. This name will be used to store the measurement data and acquired image files. Both will be saved on the computer's hard drive. Next, the system prompts the analyst to correctly place the sample on the sample holder so that the area to be measured is between two black masks. The top edge of the sample should also be at least one inch or higher above the top edge of the field of view image. Once the sample is correctly placed, the analyst continues the algorithm, and the system prompts the analyst to adjust the illumination level so that the displayed white level is set to approximately 0.95. Once set, the software algorithm then automatically acquires and saves the images, and then performs image processing and analysis steps by placing a five-grid across the image spanning the sample width (e.g., on a CD) and measuring the average gray level and gray level variation within each individual grid. This data is then exported to a previously named EXCEL spreadsheet, and the mean and standard deviation of the gray level across the entire grid are measured simultaneously again using the same grid. The algorithm then calculates the corresponding gray-level percentage coefficient of variation (GL%COV) based on this data and exports it to an Excel spreadsheet. The GL%COV calculation is as follows:

[0353] GL%COV = Standard deviation of gray level / Average gray level × 100% (1)

[0354] The measurement grid spanning the CD is approximately 66 mm wide and subdivided into five equally sized cells. Average grayscale and grayscale variation measurements are performed on each cell, while GL%COV measurements are performed on all cell combinations. After the first measurement is taken near the top of the image, the algorithm moves the grid down 2.1 cm and performs a second measurement on the same image, exporting it to an Excel spreadsheet. This is repeated twice more to measure a total of four CD running areas for each image. The algorithm then instructs the automated stage to move the sample longitudinally 8.2 cm before starting the process again to set the white level for the next image. For each sample copy, three separate images are acquired and analyzed. A total of three sample copies are then analyzed for each sample.

[0355] For grayscale variation measurements, five measurements were taken at each grid location and then averaged in an Excel spreadsheet. These averages were then accumulated across 36 different grid locations (i.e., 3 copies x 3 images x 4 CD locations = 36 CD locations) to compare different samples. After obtaining results from different samples, they can be compared with each other by performing basic statistical analyses such as a Student's t-analysis at a 90% confidence level.

[0356] Adhesive distribution test method

[0357] First, the sample to be imaged is stained with osmium tetroxide fumes, allowing the adhesive to selectively absorb sufficient amounts of osmium to facilitate better contrast with the highly absorbent polymer fibers during micro-CT imaging. The sample is placed in a sealable, airtight chamber, and a vial of osmium tetroxide is added to stain it. The chamber is then immediately sealed, allowing the osmium tetroxide to interact with the sample for at least 24 hours. Due to the high toxicity of osmium tetroxide, the staining process is performed in a fume hood. After 24 hours, the adhesive will appear strain-black. The chamber is then reopened and allowed to ventilate in a fume hood for another 24 hours to ensure that any unreacted osmium tetroxide is harmlessly released. After this second 24-hour cycle, the sample is now ready for micro-CT imaging.

[0358] A portion of the stained sample was imaged using a Bruker SkyScan Model 1272 micro-CT or equivalent. Exemplary X-ray scanning conditions included the following:

[0359] - Voltage (kV) = 35

[0360] - Current (uA) = 231

[0361] - Image pixel size (µm) = 8.0

[0362] - Rotation step size (degrees) = 0.20

[0363] -Frame average = 5

[0364] The sample must be oriented such that the machine orientation length remains vertical during the scanning process. After the initial X-ray scan, a rotating X-ray image is reconstructed using Bruker's NRecon software or equivalent software on other vendor systems. Grayscale reconstructed image slices are used for adhesive distribution analysis.

[0365] The image analysis software platform used to perform adhesive distribution measurements is QWIN Pro (version 3.2.1), available from Leica Microsystems (with offices in Heerbrugg, Switzerland). Measurements of grayscale micro-CT images are processed and performed using a custom-written image analysis algorithm, “Z-Adhesive Distribution,” written in the Quantimet user-interactive programming system (QUIPS) language. The custom image analysis algorithm shown below is executed directly on grayscale reconstructed image slices stored on the storage device. The custom image analysis algorithm is shown below.

[0366] Name: z-adhesive distribution

[0367] Objective: To measure the z-distribution of osmium-stained adhesive on ActivTech / Blizzard substrates.

[0368] Conditions: Images acquired on a Bruker SkyScan 1272 micro-CT scanner

[0369] Date: August 12, 2020

[0370] Author: DGBiggs

[0371] set up

[0372] Clear Accept

[0373] Open data file

[0374] Open the file (C:\Data\102888-Graverson\totdistribution.xls, channel #2)

[0375] Open the file (C:\Data\102888-Graverson\adhesivedistribution.xls, channel #1)

[0376] Configuration (image memory 1968x504, grayscale image 201, binary 32)

[0377] --Calvalue=8.00um / px

[0378] Calculated value = 8.00

[0379] Correction (calculated value, unit: per pixel)

[0380] Measurement frame (x 160, y 2, width 1600, height 502)

[0381] Image frame (x 0, y 0, width 1968, height 504)

[0382] Input result header

[0383] File Result Header (Channel #1)

[0384] File line (channel #1)

[0385] File Result Header (Channel #2)

[0386] File line (channel #2)

[0387] Pause text ("Enter the prefix name for the sample image file.")

[0388] Enter (title$)

[0389] File(title$, channel#1)

[0390] File line (channel #1)

[0391] For (images = 100 to 900, step 100)

[0392] Clear feature histogram #1

[0393] Clear feature histogram #3

[0394] Define binary graphics variables

[0395] GRAPHORGX = 250

[0396] Image acquisition and detection

[0397] ACQOUTPUT = 0

[0398] - Location of the micro-CT image to be analyzed

[0399] ACQFILE$="C:\Images\102888-Graverson\Code 2-Blizzard Tech Osmium\"+TITLE$+""+STR$(IMAGE)+".JPG"

[0400] Read the image (from file ACQFILE$ to ACQOUTPUT).

[0401] Color Transformation (Monochrome Mode)

[0402] - Inspect all materials

[0403] Detection (whiter than 33, from image 0 to binary 0)

[0404] Image processing

[0405] PauseText("Accepts the main structure, excluding any peripheral fragments.")

[0406] Binary edit [pause] (accepts binary 0 to binary 1, nibbles padded, width 2)

[0407] Binary modification (enabled from binary 1 to binary 1, loop 1, operator disk, and edge erosion).

[0408] Binary modification (binary 1 to binary 2 is disabled, loop 120, operator disk, edge erosion is enabled)

[0409] Binary recognition (filling holes from binary 2 to binary 3)

[0410] Binary modification (enabled from binary 3 to binary 4, loop 5, operator disk, and edge erosion).

[0411] Boolean sum measurement

[0412] For (BINGRAPH = 1 to 26, step 1)

[0413] GRAPHORGY = 2

[0414] GRAPHNX=1

[0415] GRAPHNY = 1

[0416] GRAPHWID=50

[0417] GRAPHHGHT=502

[0418] GRAPHTHIK = 1

[0419] GRAPHORNT=0

[0420] GRAPHOUT = 13

[0421] Graphics (inverted grid, GRAPHNX x GRAPHNY lines, grid size GRAPHWID x GRAPHHGHT, origin GRAPHORGX x GRAPHORGY)

[0422] Thick GRAPHTHIK, orientation GRAPHONT, until GRAPHONT is removed)

[0423] Binary logic (C = A AND B: C is binary 5, A is binary 4, B is binary 13)

[0424] YPOS Center

[0425] Measurement features (planar binary 5, 32feet, minimum area: 10, grayscale image: color 0)

[0426] Selected parameters: UserDef1, YCentroid

[0427] Feature expression (UserDef1(All Features), title CalcA = (py centroid(FTR) - 252))

[0428] GREYUTILIN=0

[0429] GREYUTILOUT=1

[0430] -Transfer grayscale image

[0431] If (PUSERDEF1(FTR)<0)

[0432] Distance = (PUSERDEF1(FTR)**2)**0.5

[0433] SHIFT.SIZE = Distance

[0434] SHIFT.DIRN=270

[0435] Gray Util(Shift GREYUTILIN to GREYUTILOUT by SHIFT.SIZE at SHIFT.DIRNdegs)

[0436] Endif

[0437] If (PUSERDEF1(FTR)>0)

[0438] Distance = PUSERDEF1(FTR)

[0439] SHIFT.SIZE = Distance

[0440] SHIFT.DIRN=90

[0441] Gray Util(Shift GREYUTILIN to GREYUTILOUT by SHIFT.SIZE at SHIFT.DIRNdegs)

[0442] Endif

[0443] If (PUSERDEF1(FTR) = 0)

[0444] Gray utility (Copy image 0 to image 1)

[0445] Endif

[0446] Display (Image 0 (On), Frame (On, On), Plane (Off, Off, Off, Off, Off, Off), LUT 0, x 0, y 0, z 1, Shrink Off)

[0447] Centering detection

[0448] - Inspecting adhesives

[0449] Detection (whiter than 84, from image 1 to binary 10)

[0450] Binary modification (binary decimal to binary decimal is off, loop 1, operator disk, edge erosion is on)

[0451] Binary modification (binary decomposition to binary 10 to binary 11 disabled, loop 1 enabled, operator disk enabled, edge erosion enabled).

[0452] - Inspect all materials

[0453] Detection (whiter than 33, from image 1 to binary 0)

[0454] Binary modification (binary 0 to binary 0 off, loop 1, operator disk, edge erosion on)

[0455] Binary modification (enabled from binary 0 to binary 0, loop 1, operator disk, and edge erosion).

[0456] Measuring the Z-distribution of the adhesive

[0457] GRAPHORGY = 2

[0458] GRAPHNX=1

[0459] GRAPHNY = 1

[0460] GRAPHWID=50

[0461] GRAPHHGHT=502

[0462] GRAPHTHIK = 1

[0463] GRAPHORNT=0

[0464] GRAPHOUT=12

[0465] Graphics (inverted grid, GRAPHNX x GRAPHNY lines, grid size GRAPHWID x GRAPHHGHT, origin GRAPHORGX x GRAPHORGY)

[0466] Thick GRAPHTHIK, orientation GRAPHONT, until GRAPHONT is removed)

[0467] Binary logic (C = A AND B: C is binary 6, A is binary 12, B is binary 11)

[0468] Measurement features (planar binary 6, 32feret, minimum area: 10, grayscale image: image 1)

[0469] Selected parameters: Area, UserDef2, YCentroid

[0470] Feature expression (UserDef2(all features), title YFEAT = py centroid(FTR) * calvalue)

[0471] Feature histogram #1 (Y Param Area, X Param UserDef2, from 0 to 4032, linear, 40 bins)

[0472] Feature histogram #2 (Y Param Area, X Param UserDef2, from 0 to 4032, linear, 40 bins)

[0473] Measure the Z-distribution of total material

[0474] Binary logic (C = A and B: C is binary 7, A is binary 12, B is binary 0)

[0475] Measurement features (planar binary 7, 32feret, minimum area: 10, grayscale image: image 1)

[0476] Selected parameters: Area, X FCP, Y FCP, UserDef2, Y centerline

[0477] Feature expression (UserDef2(all features), title YFEAT = py centroid(FTR) * calvalue)

[0478] Feature histogram #3 (Y Param Area, X Param UserDef2, from 0 to 4032, linear, 40 bins)

[0479] Feature histogram #4 (Y Param Area, X Param UserDef2, from 0 to 4032, linear, 40 bins)

[0480] GRAPHORGX = GRAPHORGX + 50

[0481] Next (BINGRAPH)

[0482] Display feature histogram results (#2, level, differential, binning + graph (Y-axis linear), statistics)

[0483] Data window (10, 871, 640, 300)

[0484] Displaying feature histogram results (#4, Level, Differential, Binning + Graph (Y-axis Linear), Statistical)

[0485] Data window (962, 880, 640, 300)

[0486] Archive the adhesive and material histogram of the current image.

[0487] Document feature histogram results (#1, Differential, Statistics, Bin Details, Channel #1)

[0488] File line (channel #1)

[0489] Document feature histogram results (#3, Differential, Statistics, Bin Details, Channel #2)

[0490] File line (channel #2)

[0491] File line (channel #2)

[0492] Measure the average substrate thickness

[0493] MFLDIMAGE=4

[0494] Measurement field (planar MFLDIMAGE, enter FLDRESULTS(1), statistics enter FLDSTATS(7,1))

[0495] Selected parameter: area

[0496] Average thickness = Field result(1) / (CALVALUE*1330)

[0497] File(“Average substrate thickness (μm)=”, Channel #1)

[0498] File(MEANTHICK, channel #1, 2 digits after '.')

[0499] File line (channel #1)

[0500] File line (channel #1)

[0501] Next (image)

[0502] Histogram of adhesives and materials accumulated for current slide archiving

[0503] Document feature histogram results (#2, Differential, Statistics, Bin Details, Channel #1)

[0504] Document feature histogram results (#4, Differential, Statistics, Bin Details, Channel #2)

[0505] Close data file

[0506] Close file (channel #1)

[0507] Close file (channel #2)

[0508] Finish

[0509] Adhesive distribution data in the z-direction was directly exported to an Excel spreadsheet. For data obtained from each analytical slice of the micro-CT image, separate histograms of adhesive and total material z-distribution were exported, along with cumulative histograms of data from all nine slices. These latter cumulative histograms were used to calculate the percentage of adhesive in each third layer of the micro-CT image thickness for a single slice. The area units shown in the histograms are square micrometers. To determine the histogram locations of the top and bottom surface boundaries of the material, a 95% wt% total area rule was used on the total material histogram. In other words, the surface boundary was considered the first histogram bin when approaching the top and bottom material edges of the histogram, encountering a minimum 2.5% wt% material area. These bin boundaries were then transposed onto the adhesive-only cumulative histogram to determine the percentage of adhesive area present in the top, middle, and bottom third-third histogram bins, including the calculated boundary bins. In cases where the number of bins was not divisible by 3 (e.g., 8, 10, 14, etc.), a rotation technique was used to calculate the percentage of adhesive in each third layer of the material. For example, in the first encounter with a layer 14 container thickness, the top layer has 4 containers, the middle layer has 5, and the bottom layer has 5. In subsequent encounters, the top layer has 5 containers, the middle layer has 4, and the bottom layer has 5. If a third encounter occurs, the bottom layer will have one less or one more bin than the top and middle layers. If a fourth encounter occurs, the top layer again becomes a layer containing one less or one more bin than the other two layers. This rotation method continues as required by the data.

[0510] The final sample mean adhesive percentage values ​​for each third layer of z-distribution depth are based on an N=7 analysis from seven separate secondary sampling zones, each with four adjacent cut cross-sections. Comparisons between different samples can be performed using a Student's T-analysis at a 90% confidence level.

[0511] All relevant portions of the documents referenced in the specific implementation are incorporated herein by reference; any reference to any document should not be construed as an admission that it is prior art concerning the invention. In the event of any conflict between the meaning or definition of any term in this written document and any meaning or definition of a term in the documents incorporated by reference, the meaning or definition assigned to the term in this written document shall prevail.

[0512] While specific embodiments of the invention have been shown and described, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Therefore, it is contemplated that all such changes and modifications falling within the scope of the invention be covered in the appended claims.

[0513] Implementation Plan

[0514] In a first embodiment, an absorbent structure having a longitudinal axis and a transverse axis may include: a first base material layer having a first surface and a second surface; a second base material layer having a first surface and a second surface; and a mixture of superabsorbent particles and an adhesive disposed between the first base material layer and the second base material layer, wherein the superabsorbent particles are disposed in an amount greater than or equal to 400 gsm and less than or equal to 600 gsm, and wherein the adhesive is disposed in an amount greater than or equal to 4% by weight and less than or equal to 6% by weight of the superabsorbent particles, wherein the adhesive forms a three-dimensional mesh structure comprising mesh adhesive filaments, the superabsorbent particles being fixed within the mesh structure, and the mesh adhesive filaments extending substantially in a three-dimensional space defined by the mesh adhesive filaments and the superabsorbent particles, and wherein, according to a pad uniformity test method, the absorbent structure has a gray-level % coefficient of variation (GL%COV) value less than or equal to 34.5.

[0515] In a second embodiment, the absorption structure described in the first embodiment may further include, according to the pad uniformity test method, a gray-level % coefficient of variation (GL%COV) value of less than or equal to 33.5.

[0516] In the third embodiment, the absorption structure in any one of the first or second embodiments may further include, wherein the superabsorbent particles are provided in an amount greater than or equal to 400 gsm and less than or equal to 500 gsm.

[0517] In the fourth embodiment, the absorption structure of any one of the first to third embodiments may further include, wherein the absorption structure does not include an adhesive layer disposed between at least one of: the first base material layer and the mixture of the superabsorbent particles and the adhesive; and the second base material layer and the mixture of the superabsorbent particles and the adhesive.

[0518] In the fifth embodiment, the absorption structure of any one of the first to fourth embodiments may further include, wherein the mesh adhesive filaments contact substantially all of the superabsorbent particles in the mixture of the superabsorbent particles and the adhesive.

[0519] In a sixth embodiment, an absorbent structure having a longitudinal axis and a transverse axis may include: a first base material layer having a first surface and a second surface; a second base material layer having a first surface and a second surface; and a mixture of superabsorbent particles and an adhesive disposed between the first base material layer and the second base material layer, wherein the superabsorbent particles are disposed in an amount greater than or equal to 400 gsm and less than or equal to 500 gsm, and wherein the adhesive is disposed in an amount greater than or equal to 4% by weight and less than or equal to 6% by weight of the superabsorbent particles, wherein the adhesive forms a three-dimensional mesh structure comprising mesh adhesive filaments, the superabsorbent particles being fixed within the mesh structure, and the mesh adhesive filaments extending substantially in a three-dimensional space defined by the mesh adhesive filaments and the superabsorbent particles, and wherein, according to a pad uniformity test, the absorbent structure has a CD gray level variation (CD GLVar.) value less than or equal to 510.

[0520] In the seventh embodiment, the absorption structure described in the sixth embodiment may further include, according to the pad uniformity test, the absorption structure having a CD gray level variation (CD GL Var.) value of less than or equal to 490.

[0521] In the eighth embodiment, the absorption structure of the sixth or seventh embodiment may further include, wherein the absorption structure does not include an adhesive layer disposed between at least one of: the first base material layer and the mixture of the superabsorbent particles and the adhesive; and the second base material layer and the mixture of the superabsorbent particles and the adhesive.

[0522] In the ninth embodiment, the absorption structure of any one of the sixth to eighth embodiments may further include, wherein the mesh adhesive filaments contact substantially all of the superabsorbent particles in the mixture of the superabsorbent particles and the adhesive.

[0523] In a tenth embodiment, a method of manufacturing an absorbent structure may include: supplying a first superabsorbent particle stream to a first substrate material layer moving in a machine direction, the first superabsorbent particle stream having a first side and a second side; 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, the first adhesive contacting the first superabsorbent particle stream at a first contact point having a first height measured from the first substrate material layer; and spraying a second adhesive onto the second side of the first superabsorbent particle stream using a second adhesive applicator having a second adhesive nozzle, the second adhesive contacting the first superabsorbent particle stream and mixing with the first superabsorbent particles of the first superabsorbent particle stream before the superabsorbent particles are deposited onto the first substrate material layer. The superabsorbent particles of the absorbent particle stream are mixed, and the second binder contacts the first superabsorbent particle stream at a second contact point having a second height measured from the first substrate material layer. The mixed superabsorbent particles of the first superabsorbent particle stream, the first binder, and the second binder are deposited onto the first substrate material layer. The mixture of the superabsorbent particles, the first binder, and the second binder of the first superabsorbent particle stream is covered with a second substrate material layer. The mixture of the superabsorbent particles, the binder, the first substrate material layer, and the second substrate material layer is separated into individual absorbent structures. The absorbent structure prepared by the method, having superabsorbent particles set in an amount equal to 300 gsm and binder set in an amount greater than 3% by weight and less than 4% by weight of the superabsorbent particles, has a CD gray level variation (CD GL Var.) value of less than or equal to 675, according to the pad uniformity test.

[0524] In the eleventh embodiment, the method of the tenth embodiment may further include, according to the pad uniformity test, the absorbent structure prepared by the method having superabsorbent particles set in an amount equal to 300 gsm and an adhesive set in an amount greater than 3 wt% and less than 4 wt% of the weight of the superabsorbent particles having a CD gray level variation (CD GL Var.) value of less than or equal to 625.

[0525] In the twelfth embodiment, the method described in the tenth embodiment or the eleventh embodiment may further include, according to the pad uniformity test, an absorbent structure prepared by the method having superabsorbent particles set in an amount equal to 400 gsm and an adhesive set in an amount greater than 4 wt% and less than 5 wt% of the weight of the superabsorbent particles having a CD gray level variation (CD GL Var.) value of less than or equal to 585.

[0526] In the thirteenth embodiment, the method of any one of the tenth to twelfth embodiments may further include, according to the pad uniformity test, an absorbent structure prepared by the method having superabsorbent particles set in an amount equal to 400 gsm and an adhesive set in an amount greater than 4% by weight and less than 5% by weight of the superabsorbent particles having a CD gray level variation (CD GL Var.) value of less than or equal to 500.

[0527] In the fourteenth embodiment, the method of any one of the tenth to thirteenth embodiments may further include, according to the pad uniformity test, an absorbent structure prepared by the method having superabsorbent particles set in an amount equal to 500 gsm and an adhesive set in an amount of 6% by weight of the superabsorbent particles having a CD gray level variation (CD GL Var.) value of less than or equal to 500.

[0528] In the fifteenth embodiment, the method of any one of the tenth to fourteenth embodiments may further include, according to the pad uniformity test, an absorbent structure prepared by the method having superabsorbent particles set in an amount equal to 600 gsm and an adhesive set in an amount of 6% by weight of the superabsorbent particles having a CD gray level variation (CD GL Var.) value of less than or equal to 450.

[0529] In the sixteenth embodiment, the method of any one of the tenth to fifteenth embodiments may further include, wherein the first height is different from the second height.

[0530] In the seventeenth embodiment, the method of any one of the tenth to sixteenth embodiments may further include wherein the first height is located between 4 mm and 40 mm from the first substrate material.

[0531] In the eighteenth embodiment, the method of any one of the tenth to sixteenth embodiments may further include, wherein the first height and the second height are spaced between 3 mm and 9.5 mm.

[0532] In the nineteenth embodiment, the method of any one of the tenth to eighteenth embodiments, 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, may further include: supplying a second superabsorbent particle stream having a first side and a second side to the deposited mixture of the superabsorbent particles and the first adhesive of the first superabsorbent particle stream; spraying a third adhesive onto the first side of the second superabsorbent particle stream using a third adhesive applicator having a third adhesive nozzle; the third adhesive contacting the second superabsorbent particle stream and mixing with the superabsorbent particles of the second superabsorbent particle stream before the superabsorbent particles are deposited onto the deposited mixture of the superabsorbent particles, the first adhesive, and the second adhesive of the first superabsorbent particle stream; and spraying a third adhesive onto the second side of the second superabsorbent particle stream using a fourth adhesive applicator having a fourth adhesive nozzle. A fourth adhesive is applied to the side, the fourth adhesive contacting the second superabsorbent particle stream and mixing 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 of the first superabsorbent particle stream. The mixed superabsorbent particles, the second adhesive, and the fourth adhesive of the second superabsorbent particle stream are deposited onto the mixture of the superabsorbent particles, the first adhesive, and the third adhesive of the first superabsorbent particle stream and the mixture of the superabsorbent particles, the second adhesive, and the fourth adhesive of the second superabsorbent particle stream. A second base material layer covers the superabsorbent particles, the first adhesive, the third adhesive, and the mixture of the superabsorbent particles, the second adhesive, and the fourth adhesive of the second superabsorbent particle stream, and separates the superabsorbent particles, the adhesive, the first base material layer, and the mixture of the second base material layer into individual absorbent structures.

[0533] In a twentieth embodiment, the method of the nineteenth embodiment may further include, 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, and 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, wherein the third height is different from the fourth height.

Claims

1. An absorption structure having a longitudinal axis and a transverse axis, the absorption structure comprising: A first substrate material layer, the first substrate material layer having a first surface and a second surface; A second substrate material layer, the second substrate material layer having a first surface and a second surface; as well as A mixture of superabsorbent particles and an adhesive, the mixture being disposed between a first substrate material layer and a second substrate material layer. The superabsorbent particles are provided in an amount greater than or equal to 400 gsm and less than or equal to 600 gsm, and the binder is provided in an amount greater than or equal to 4% by weight and less than or equal to 6% by weight of the superabsorbent particles. The adhesive forms a three-dimensional network structure comprising network adhesive filaments, wherein the superabsorbent particles are fixed within the network structure, and the network adhesive filaments extend substantially within a three-dimensional space defined by the network adhesive filaments and the superabsorbent particles. According to the pad uniformity test method, the absorption structure has a gray level coefficient of variation (GL %COV) value of less than or equal to 34.

5. The method for manufacturing the absorption structure includes the following steps: A first superabsorbent particle stream is supplied 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 with 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 is different from the second height.

2. The absorption structure as claimed in claim 1, wherein, according to the pad uniformity test method, the absorption structure has a gray level coefficient of variation (GL %COV) value of less than or equal to 33.

5.

3. The absorption structure as claimed in claim 1, wherein the superabsorbent particles are provided in an amount greater than or equal to 400 gsm and less than or equal to 500 gsm.

4. The absorption structure of claim 1, wherein the absorption structure does not include an adhesive layer disposed between at least one of: the first base material layer and the mixture of the superabsorbent particles and the adhesive; and the second base material layer and the mixture of the superabsorbent particles and the adhesive.

5. The absorption structure of claim 1, wherein the mesh adhesive filaments contact substantially all of the superabsorbent particles in the mixture of the superabsorbent particles and the adhesive.

6. An absorption structure having a longitudinal axis and a transverse axis, the absorption structure comprising: A first substrate material layer, the first substrate material layer having a first surface and a second surface; A second substrate material layer, the second substrate material layer having a first surface and a second surface; as well as A mixture of superabsorbent particles and an adhesive, the mixture being disposed between a first substrate material layer and a second substrate material layer, wherein the superabsorbent particles are disposed in an amount greater than or equal to 400 gsm and less than or equal to 500 gsm, and wherein the adhesive is disposed in an amount greater than or equal to 4% by weight and less than or equal to 6% by weight of the superabsorbent particles. The adhesive forms a three-dimensional network structure comprising network adhesive filaments, wherein the superabsorbent particles are fixed within the network structure, and the network adhesive filaments extend substantially within a three-dimensional space defined by the network adhesive filaments and the superabsorbent particles. According to the pad uniformity test, the absorption structure has a cross-machine direction gray level variation (CD GL Var.) value of less than or equal to 510; The method for manufacturing the absorption structure includes the following steps: A first superabsorbent particle stream is supplied 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 with 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 is different from the second height.

7. The absorption structure of claim 6, wherein, according to the pad uniformity test, the absorption structure has a cross-machine direction gray level variation (CD GL Var.) value of less than or equal to 490.

8. The absorption structure of claim 6, wherein the absorption structure does not include an adhesive layer disposed between at least one of: the first base material layer and the mixture of the superabsorbent particles and the adhesive; and the second base material layer and the mixture of the superabsorbent particles and the adhesive.

9. The absorption structure of claim 6, wherein the mesh adhesive filaments contact substantially all of the superabsorbent particles in the mixture of the superabsorbent particles and the adhesive.

10. A method for manufacturing an absorbent structure, the method comprising: A first superabsorbent particle stream is supplied 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 with 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 superabsorbent particles, the first binder, and the second binder of the first superabsorbent particle stream are deposited onto the first substrate material layer. The mixture of the superabsorbent particles, the first adhesive, and the second adhesive in the first superabsorbent particle stream is covered by a second substrate material layer; and The mixture of the superabsorbent particles, binder, first substrate material layer, and second substrate material layer is separated into individual absorbent structures. According to the pad uniformity test, the absorbent structure prepared by the method, having superabsorbent particles set in an amount equal to 300 gsm and an adhesive set in an amount greater than 3% by weight and less than 4% by weight of the superabsorbent particles, has a cross-machine direction gray level variation (CD GL Var.) value of less than or equal to 675. The first height is different from the second height.

11. The method of claim 10, wherein, according to the pad uniformity test, the absorbent structure prepared by the method having superabsorbent particles set in an amount equal to 300 gsm and an adhesive set in an amount greater than 3% by weight and less than 4% by weight of the superabsorbent particles has a cross-machine direction gray level variation (CD GL Var.) value of less than or equal to 625.

12. The method of claim 10, wherein, according to the pad uniformity test, the absorbent structure prepared by the method having superabsorbent particles set in an amount equal to 400 gsm and an adhesive set in an amount greater than 4% by weight and less than 5% by weight of the superabsorbent particles has a cross-machine direction gray level variation (CD GL Var.) value of less than or equal to 585.

13. The method of claim 10, wherein, according to the pad uniformity test, the absorbent structure prepared by the method having superabsorbent particles set in an amount equal to 400 gsm and an adhesive set in an amount greater than 4% by weight and less than 5% by weight of the superabsorbent particles has a cross-machine direction gray level variation (CD GL Var.) value of less than or equal to 500.

14. The method of claim 10, wherein, according to the pad uniformity test, the absorbent structure prepared by the method having superabsorbent particles set in an amount equal to 500 gsm and an adhesive set in an amount of 6% by weight of the superabsorbent particles has a cross-machine direction gray level variation (CD GL Var.) value of less than or equal to 500.

15. The method of claim 10, wherein, according to the pad uniformity test, the absorbent structure prepared by the method having superabsorbent particles set in an amount equal to 600 gsm and an adhesive set in an amount of 6% by weight of the superabsorbent particles has a cross-machine direction gray level variation (CD GL Var.) value of less than or equal to 450.

16. The method of claim 10, wherein the first height is located between 4 mm and 40 mm from the first substrate material layer.

17. The method of claim 10, wherein the first height and the second height are spaced between 3 mm and 9.5 mm apart.

18. The method of claim 10, 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 second superabsorbent particle stream is supplied to the mixture of the superabsorbent particles of the first superabsorbent particle stream and the deposited first binder, 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 superabsorbent particles of the first superabsorbent particle stream, the first adhesive, and the second adhesive. A fourth adhesive is sprayed onto the second side of the second superabsorbent particle stream using a fourth adhesive applicator with a fourth 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 superabsorbent particles of the first superabsorbent particle stream, the first adhesive, and the second adhesive. The superabsorbent particles, the second binder, and the fourth binder of the second superabsorbent particle stream are deposited onto the superabsorbent particles, the first binder, and the third binder of the first superabsorbent particle stream. The superabsorbent particles of the first superabsorbent particle stream, the first adhesive and the third adhesive, and the superabsorbent particles of the second superabsorbent particle stream, the second adhesive and the fourth adhesive deposited thereon are covered with a second base material layer. as well as The mixture of the superabsorbent particles, the binder, the first substrate material layer, and the second substrate material layer is separated into individual absorbent structures.

19. The method of claim 18, 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 height is different from the fourth height.

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