Absorbent article with wrapped absorbent core

Abstract

An absorbent article includes a body-side liner, an outer cover, and an absorbent assembly between the body-side liner and the outer cover. The absorbent core is disposed within an intermediate shell of the nonwoven wrap. A front extension extends from a front portion of the intermediate housing and a rear extension extends from a rear portion of the intermediate housing. One or both of the front and rear extensions of the nonwoven wrap are folded over itself to facilitate sealing the absorbent core within the nonwoven wrap.

Description

Background Technology

[0001] Personal care absorbent products, such as diapers and incontinence underwear, often include an absorbent core that rapidly absorbs bodily fluids (e.g., urine) and traps the fluid within to limit its retransmission to the wearer. The absorbent core may include wood pulp fibers and superabsorbent materials for absorbing fluids.

[0002] The characteristics of the absorbent core can influence consumers' perception of personal care absorbent products. For example, some consumers prefer the soft feel of a lower-density, higher-loft absorbent core compared to a conventional, higher-density, lower-loft core. However, manufacturing personal care absorbent products with lower-density, higher-loft absorbent cores presents challenges. For instance, the fibers and / or superabsorbent materials in such cores can cause displacement and deformation of the absorbent layer during manufacturing.

[0003] Absorbent articles with a low-density, high-loft absorbent core and a characteristic structure for maintaining the shape of the absorbent core during manufacturing would be useful. Summary of the Invention

[0004] Generally, this disclosure relates to an absorbent assembly having an absorbent core disposed within a nonwoven wrapper. Furthermore, one or more extensions of the foldable nonwoven wrapper help seal the absorbent core within the nonwoven wrapper. Such a seal can help limit the movement of lint and / or superabsorbent material during high-speed manufacturing of the absorbent article. For example, the folded extensions can limit or prevent material in the soft, low-density absorbent core from leaving or being “squeezed out” from the nonwoven wrapper due to the impact of a blade folding machine during high-speed manufacturing of the absorbent article.

[0005] In one example embodiment, the absorbent article includes a side liner, an outer cover, and an absorbent assembly located between the side liner and the outer cover. The absorbent assembly includes a nonwoven wrap and an absorbent core. The nonwoven wrap includes an intermediate shell, a front extension, and a rear extension. The absorbent core is disposed within the intermediate shell of the nonwoven wrap. The front extension extends from the front of the intermediate shell, and the rear extension extends from the rear of the intermediate shell. One or both of the front and rear extensions of the nonwoven wrap are folded over itself.

[0006] In another example embodiment, a method for forming an absorbent article includes: forming a plurality of discrete absorbent cores on a nonwoven wrapping fiber web to form a composite fiber web; cutting the composite fiber web between the discrete absorbent cores to form a plurality of absorbent assemblies, each absorbent assembly including a nonwoven wrapping and an absorbent core disposed within an intermediate shell of the nonwoven wrapping in each absorbent assembly; folding at least one of a front extension or a rear extension of each nonwoven wrapping; and joining the plurality of absorbent assemblies between a body-side liner and an outer cover.

[0007] These and other features, aspects, and advantages of this disclosure will be better understood by referring to the following description and the appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and, together with the description, serve to explain the principles of the disclosure. Attached Figure Description

[0008] The complete and practical disclosure of this disclosure, including its best mode, is set forth in the specification to those skilled in the art, with reference to the accompanying drawings.

[0009] Figure 1 A top view of an absorbent article in a stretched and flat arrangement according to an example aspect of this disclosure;

[0010] Figure 2 yes Figure 1 A top view of the absorbent component of an example absorbent article;

[0011] Figure 3 yes Figure 1 The example absorbs a schematic partial sectional view of clothing;

[0012] Figure 4 This is a schematic partial cross-sectional view of an absorbent garment according to another example embodiment;

[0013] Figure 5 This is a schematic partial cross-sectional view of an absorbent garment according to another example embodiment;

[0014] Figure 6 This is a schematic side view of a method and apparatus according to an exemplary aspect of this disclosure;

[0015] Figure 7 yes Figure 6 Another schematic side view of the example method and device;

[0016] Figure 8 This is a schematic side view of a forming cylinder according to an exemplary aspect of this disclosure; and

[0017] Figure 9 This is an exemplary composite fiber web formed during an intermediate step of the method according to an exemplary aspect of this disclosure, wherein portions are cut away to exhibit the following characteristics; and

[0018] Figure 10 yes Figure 6 Example method and another schematic side view of the device.

[0019] The repeated use of reference numerals in this specification and drawings is intended to indicate the same or similar features or elements of the invention. Detailed Implementation

[0020] This disclosure relates throughout to absorbent articles in which an absorbent assembly is located between a body-side inner liner and an outer cover. The absorbent assembly includes a nonwoven wrap and an absorbent core. The absorbent core is disposed within an intermediate shell of the nonwoven wrap, and a front and / or rear extension of the nonwoven wrap is foldable, for example, folded over the intermediate shell of the nonwoven wrap. Such folding of the nonwoven wrap can help maintain the shape of the absorbent core during the manufacture of the absorbent article. Furthermore, such folding of the nonwoven wrap can help limit the movement of the fibers and / or superabsorbent material of the absorbent core during the manufacture of the absorbent article, such as when folding the absorbent article with a blade-type folding machine. Those skilled in the art will understand that this discussion is merely a description of exemplary embodiments and is not intended to limit the broader aspects of this disclosure.

[0021] 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 elements. As used herein, the terms “comprising” and “including” are intended to be inclusive in a manner similar to the term “containing.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). As used herein throughout the specification and claims, approximate language is applied to modify any quantitative expression that allows for variation without altering its underlying function. Thus, values ​​modified by one or more terms such as “about,” “approximately,” and “substantially” are not limited to specified precise values. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value. For example, approximate language may refer to a range of ten percent (10%).

[0022] definition :

[0023] The term "absorbent article" herein refers to an article that can be placed close to or adjacent to the wearer's body (i.e., adjacent to the body) to absorb and contain various liquid, solid, and semi-solid excretions from the body. As described herein, such absorbent articles are intended to be discarded after a limited period of use, rather than washed or, in other words, recovered for reuse. It should be understood that this disclosure applies to a wide range of disposable absorbent articles, including but not limited to diapers, diaper pants, training pants, teen pants, swim trunks, feminine hygiene products (including but not limited to menstrual pads or menstrual pants), incontinence products, medical clothing, surgical pads and bandages, other personal care or healthcare clothing, without departing from the scope of this disclosure.

[0024] The term "bonding" in this article refers to the joining, adhesion, connection, attachment, etc., of two components. When two components are joined, adhered, connected, attached, etc., directly or indirectly to each other, such as when each component is directly bonded to an intermediate component, they will be considered bonded together.

[0025] The term "carded fiber web" as used herein refers to a fiber web containing natural or synthetic short fibers, typically with a fiber length of less than about one hundred millimeters (100 mm). Bundles of short fibers may undergo an opening process to separate the fibers, which are then fed to a carding process that separates and cards the fibers to align them longitudinally, after which the fibers are deposited onto a moving thread for further processing. Such fiber webs typically undergo some type of bonding process, such as thermal bonding using heat and / or pressure. Alternatively, the fibers may undergo an adhesive process to bond them together, such as by using powdered adhesives. Carded fiber webs may undergo fluid entanglement, such as hydroentanglement, to further entangle the fibers, thereby improving the integrity of the carded fiber web. Because the fibers are aligned longitudinally, a carded fiber web, once bonded, will typically have a greater longitudinal strength than its lateral strength.

[0026] The term "elastic" and its derivatives refer to a material or component that typically recovers its shape after deformation when the deformation force is removed. Specifically, as used herein, the term elastic or elastomer refers to any material or component that, when a biasing force is applied, allows the material or component to be stretched to a biased length of at least about 125% of its relaxed unbiased length, i.e., 1.25 times, and recovers at least 40% of its elongation upon release of the stretching force.

[0027] As used herein, the term "fiber" refers to an elongated extrusion formed by passing a polymer through a forming orifice (such as a die). Unless otherwise specified, the term "fiber" includes discontinuous fibers with a defined length and substantially continuous filaments. For example, substantially continuous filaments may have a length much greater than their diameter, such as greater than about 15,000:1, and in some cases, a length-to-diameter ratio ("aspect ratio") greater than about 50,000:1. Fibers are "hollow" to such an extent that they contain a hollow cavity extending longitudinally along at least a portion of the fiber. In some cases, the cavity may extend along the entire length of the fiber.

[0028] The term "membrane" as used herein refers to a thermoplastic membrane made using extrusion and / or forming processes, such as cast film or blown film extrusion processes. This term includes open-cell 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.

[0029] The term “gsm” in this article refers to grams per square meter.

[0030] The term "hydrophilicity" in this document refers to the wetting of a fiber or fiber surface by an aqueous liquid in contact with the fiber. The degree of wetting of a material can be described by the contact angle and surface tension of the liquid and the material involved. Apparatus and techniques suitable for measuring the wettability of specific fiber materials or blends of fiber materials are available from the Cahn SFA-222 Surface Force Analyzer System or substantially equivalent systems. When measured with this system, fibers with a contact angle less than 90° are designated as "wettable" or hydrophilic, and fibers with a contact angle greater than 90° are designated as "non-wettable" or hydrophobic.

[0031] The term “liquid impermeable” in this document refers to a laminate of one or more layers in which liquid bodily excretions such as urine will not pass through the layer or laminate at the point of liquid contact in a direction generally perpendicular to the plane of the layer or laminate under normal use conditions.

[0032] The term “liquid-permeable” in this document refers to any material through which liquids can pass.

[0033] The term "meltblown fiber" herein refers to fibers formed by extruding molten thermoplastic material as molten filaments or filaments through multiple fine, typically circular, die capillaries into a converging, high-velocity stream of heated gas (e.g., air). This high-velocity stream of heated gas draws the filaments of the molten thermoplastic material to reduce their diameter, which may be the diameter of a microfiber. The meltblown fibers are then carried by the high-velocity gas stream and deposited onto a collection surface to form a fiber web 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 can be continuous or discontinuous microfibers, typically smaller than about 0.6 denier, and can be sticky and self-adhesive when deposited onto a collection surface.

[0034] The term "nonwoven material" in this document refers to materials and material fiber webs formed without the aid of textile weaving or knitting processes. Materials and material fiber webs may have the structure of individual fibers, filaments, or strands (collectively referred to as "fibers") that may be interwoven, but not in a manner identifiable in knitted fabrics. Nonwoven materials or fiber webs can be formed by a variety of methods, such as, but not limited to, meltblown, spunbond, and carded web formation.

[0035] The term "flexible" in this article refers to a material that is supple and will easily conform to the general shape and contour of the wearer's body.

[0036] The term "spunbond" herein refers to small-diameter fibers formed by extruding molten thermoplastic material into filaments from multiple fine capillaries having a circular or other configuration of spinneret, and then rapidly reducing the diameter of the extruded filaments by conventional methods, such as, for example, jet stretching, and methods described in 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 about 0.3, and in one embodiment, between about 0.6, 5, and 10 and about 15, 20, and 40. The spunbond fibers are generally not sticky when deposited onto the collection surface.

[0037] The term "superabsorbent" herein refers to a water-swellable, water-insoluble organic or inorganic material capable, under most favorable conditions, of absorbing at least about fifteen (15) times its weight and, in one respect at least about thirty (30) times its weight, of a water-swellable, water-insoluble organic or inorganic material 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.

[0038] The term "thermoplastic" in this article refers to a material that softens and can be molded when exposed to heat and substantially returns to its unsoftened state when cooled.

[0039] The terms "user" or "caregiver" in this document refer to a person who wears or adorns one of these absorbent products, such as, but not limited to, diapers, diaper pants, training pants, teen pants, incontinence products, or other absorbent products. The user and the wearer may be the same person.

[0040] Absorbent products :

[0041] Figure 1 An example embodiment of an absorbent article 20 in a flat arrangement is shown. The surface of the article 20 in contact with the wearer is... Figure 1Facing the observer. The absorbent article 20 may define a front portion 22, a rear portion 24, and a crotch portion 26 connecting the front portion 22 and the rear portion 24. The front portion 22 may define a front waist region 23 and include a front waist edge 41. The rear portion 24 may define a rear waist region 25 and include a rear waist edge 43. The absorbent article 20 may also define a longitudinal direction 48 and a lateral direction 50, for example, they are perpendicular to each other. The absorbent article 20 may include a side liner 30, an outer cover 32, and an absorbent assembly 34 located between the side liner 30 and the outer cover 32. In various example embodiments, the side liner 30 may include one or more openings 31.

[0042] The absorbent assembly 34 may include an absorbent core 80 and at least one nonwoven wrapper 84. The absorbent core 80 may have a front edge 81 and a rear edge 82. The front edge 81 and rear edge 82 of the absorbent core 80 may be generally parallel and opposite in the longitudinal direction 48. The absorbent core 80 may also have laterally opposite side edges 83. The nonwoven wrapper 84 may have a front edge 85 and a rear edge 86. The front edge 85 and rear edge 86 of the nonwoven wrapper 84 may be generally parallel and opposite in the longitudinal direction 48. The nonwoven wrapper 84 may also have laterally opposite side edges 87.

[0043] The region between the front edge 85 of the nonwoven wrap and the front edge 81 of the absorbent core may define a front extension 90. The region between the front edge 81 and the rear edge 82 of the absorbent core may define a nonwoven wrap region or intermediate shell 92. The region between the rear edge 82 of the absorbent core and the rear edge 86 of the nonwoven wrap may define a rear extension 94. In an example embodiment, such as Figure 2 As shown, the intermediate housing 92 can extend longitudinally between the front portion 96 and the rear portion 97 along the longitudinal direction 48. The front extension 90 can extend longitudinally from the front portion 96 of the intermediate housing 92, for example at the front edge 81 of the absorber core, and the rear extension 94 can extend longitudinally from the rear portion 97 of the intermediate housing 92, for example at the rear edge 86 of the absorber core.

[0044] As used herein, "front" refers to the portion of the absorbent article 20 that is typically located at the front of the wearer during use. "Front waist area" refers to the portion of the front section that is typically located near the waist opening. "Back" refers to the portion of the absorbent article 20 that is typically located at the back of the wearer during use. "Back waist area" refers to the portion of the back section that is typically located near the waist opening. "Crotch area" refers to the portion that is typically located between the wearer's legs during use.

[0045] The crotch portion 26 may have opposing longitudinal sides 28, which include a pair of resilient, longitudinally extending leg cuffs 36. The leg cuffs 36 are generally adapted to conform to the wearer's legs during use and act as a mechanical barrier against the lateral flow of bodily effusions. The leg cuffs 36 may be resilient via leg elastic members 38. The absorbent article 20 may also include a front waist elastic member 40 and / or a rear waist elastic member 42. The rear portion 24 of the absorbent article 20 may also include a fastener 44 configured to hold the absorbent article 20 around the wearer's waist during use. The absorbent article 20 may also include a pair of receiving flaps extending longitudinally along the absorbent article 20 and are also adapted to provide a barrier against the flow of bodily effusions. It should be appreciated that various components of the absorbent article 20, such as the elastic members, may be optional, depending on the intended use of the absorbent article 20.

[0046] The side liner 30 of the absorbent article 20 may suitably provide a body-facing surface that is designed to be worn close to the wearer's body and is soft, gentle to the touch, and non-irritating to the wearer's skin. Furthermore, the side liner 30 may be less hydrophilic than the absorbent assembly 34 to provide a relatively dry surface to the wearer, and may be porous enough to be liquid-permeable, allowing liquids to easily pass through the thickness of the side liner 30. Suitable side liners 30 may be made of a variety of fibrous materials, such as porous foam, mesh foam, porous plastic film, natural fibers (e.g., wood or cotton), synthetic fibers (e.g., polyester or polypropylene), or combinations of natural and synthetic fibers. The side liner 30 may suitably help to insulate the wearer's skin from the fluids retained in the absorbent assembly 34.

[0047] Various woven and nonwoven fabrics can be used for the body side liner 30. For example, the body side liner 30 can be composed of a meltblown or spunbond web of polyolefin fibers. The body side liner 30 can also be a bonded carded web composed of natural and / or synthetic fibers. The body side liner 30 can be composed of a substantially hydrophobic material, and the hydrophobic material can optionally be treated with a surfactant or otherwise processed to impart a desired level of wettability and hydrophilicity. The body side liner 30 may have one or more pores 31 that extend partially or completely through the thickness of the liner 30. In some example embodiments, the body side liner 30 may have a plurality of pores 31 adapted to receive urine and / or feces.

[0048] The outer cover 32 of the absorbent article 20 may suitably be made of a liquid-permeable or liquid-impermeable material. Generally, it is preferred that the outer cover 32 be formed of a substantially fluid-impermeable material. For example, the outer cover 32 may be made of a thin plastic film or other flexible, liquid-impermeable material. For example, the outer cover 32 may be formed of a polyethylene film. If it is desired that the outer cover 32 have a more garment-like feel, the outer cover 32 may comprise a polyethylene film having a nonwoven fiber web laminated to its outer surface, such as a spunbond fiber web of polyolefin fibers.

[0049] Furthermore, the outer cover 32 may be formed of a woven or nonwoven fiber web that has been fully or partially constructed or treated to impart a desired level of liquid impermeability to selected areas adjacent to or near the absorber assembly 34. Additionally, the outer cover 32 may optionally be made of a microporous "breathable" material that allows vapors to escape from the composite absorber assembly 34 while still preventing liquid effluent from permeating through the outer cover 32.

[0050] The body side liner 30 and the outer cover 32 can typically be joined together to form a pocket in which the absorbent assembly 34 is located. The body side liner 30 and the outer cover 32 can be joined directly to each other around the periphery of the absorbent article 20 by any suitable mechanism, such as adhesive bonding, ultrasonic bonding, thermal bonding, pressure bonding, and combinations thereof. For example, a uniform, continuous layer of adhesive, a patterned layer of adhesive, a sprayed or meltblown pattern of adhesive, or an array of lines, swirls, or spots of adhesive can be used to join the body side liner 30 to the outer cover 32. In some example embodiments, the outer cover 32 may comprise a full-fiber web spray of adhesive that substantially covers the entire outer cover 32. The full-fiber web spray may be adapted to join both the outer cover 32 to the body side liner 30 and / or the nonwoven wrap 84 and / or the absorbent core 80.

[0051] Such bonding can also be applied to other components that bond the absorbent assembly 34 and absorbent article 20 of the present invention. The leg cuff 36 may suitably be formed from a portion of the outer cover 32 and / or the body-side liner 30, extending beyond the longitudinal side of the composite absorbent assembly 34. Of course, the leg cuff 36 may also be formed from a separate material that bonds to the outer cover 32 and / or the body-side liner 30.

[0052] The leg cuff 36 may include a leg elastic member 38. Waist elastic members 40 and 42 may also be provided. The leg elastic member 38 may be arranged to pull and hold the absorbent article 20 against and hold it against the wearer's legs. Waist elastic members 40 and 42 may also be arranged to pull and hold the absorbent article 20 against and hold it against the wearer's body. In some example embodiments, the absorbent article 20 may include a back waist elastic member 42 extending substantially across the entire width of the article. Example materials for the elastic members include strands or strips of polymeric elastomeric material that adhere to the absorbent article 20 in a stretched position or attach to the absorbent article when the article is pleated, such that an elastic contractile force is imparted to the absorbent article 20. In a particular example aspect, the elastic member may consist of individual LYCRA strands commercially available from INVISTA Co. (a company with offices in Wichita, Kans., USA).

[0053] The leg elastic member 38 and the waist elastic members 40 and 42 can have any configuration to provide the desired performance. For example, the leg elastic member 38 and the waist elastic members 40 and 42 may comprise a single strand of elastic material, or may comprise several parallel or non-parallel strands of elastic material. The leg elastic member 38 may be generally straight or optionally curved to more closely conform to the contours of the wearer's legs and hips and better accommodate bodily exudates. The leg elastic member 38 and the waist elastic members 40 and 42 can be attached to the absorbent article 20 in any of a variety of ways. For example, the elastic members may be attached to the absorbent article 20 by ultrasonic bonding, thermal bonding, pressure bonding, adhesive bonding, or combinations thereof.

[0054] Fastener 44 typically engages with the corner of the rear portion 24 of the absorbent article 20 to provide a mechanism for holding the article 20 on the wearer. Suitable fasteners 44 include fasteners with protruding tabs, hook and loop fasteners, mushroom-loop fasteners, snaps, pins, straps, and combinations thereof. Typically, fastener 44 is configured to selectively repeat fastening. It should also be understood that fastener 44 may be omitted in absorbent articles having a given design configuration.

[0055] In some example embodiments, the fastener 44 may be adapted to engage or otherwise connect to the fastener landing material 45. In some example embodiments, the fastener landing material 45 includes a ring material in the front waist region 23 that engages with the outer cover 32 and is adapted to engage the hook-type fastener 44. In other example embodiments, the outer cover 32 may serve as the fastener landing material 45 and may be adapted to engage the hook-type fastener 44. In other example embodiments, the fastener landing material 45 may be a membrane adapted to engage with the protruding fastener 44.

[0056] Absorbent assembly 34 may be located between body-side inner liner 30 and outer cover 32 to form absorbent article 20. Absorbent assembly 34 is generally conformal and capable of absorbing and retaining bodily excretions. Absorbent assembly 34 may include absorbent core 80 and at least one nonwoven wrap 84. Absorbent core 80 may be a single monolithic sheet of material or may include multiple separate, independent sheets of material operably assembled together.

[0057] The absorbent core 80 may have any of a variety of shapes and sizes. The absorbent core 80 may suitably comprise various types of wettable hydrophilic fibrous materials. Examples of suitable materials include naturally occurring organic fibers composed of inherently wettable materials, such as cellulose fibers; synthetic fibers composed of cellulose or cellulose derivatives, such as rayon fibers; inorganic fibers composed of inherently wettable materials, such as glass fibers; synthetic fibers made of inherently wettable thermoplastic polymers, such as specific polyester and polyamide fibers; and synthetic fibers composed of non-wettable thermoplastic polymers, such as polypropylene fibers, which have been hydrophilized. The absorbent core 80 may also comprise selected blends of the various types of fibers described above. The absorbent core 80 may comprise a matrix of hydrophilic fibers, such as a cellulose fiber web, mixed with particles of highly absorbent materials, such as materials commonly referred to as superabsorbent materials.

[0058] Suitable organic materials for use as superabsorbent materials in connection with this invention may include natural materials such as agar, pectin, guar gum, etc.; and synthetic materials such as synthetic hydrogel polymers. Such hydrogel polymers include, for example, alkali metal salts of polyacrylic acid, polyacrylamide, polyvinyl alcohol, ethylene maleic anhydride copolymers, polyvinyl ether, methylcellulose, carboxymethylcellulose, hydroxypropylcellulose, polyvinylmorpholinone; and polymers and copolymers of vinyl sulfonic acid, polyacrylates, polyacrylamide, polyvinylpyridine, etc. Other suitable polymers include hydrolyzed acrylonitrile-grafted starch, acrylic acid-grafted starch and isobutylene maleic anhydride polymers, and mixtures thereof. The hydrogel polymer is preferably lightly crosslinked to make the material substantially insoluble in water. Crosslinking can be achieved, for example, by radiation or by covalent bonding, ionic bonding, van der Waals bonding or hydrogen bonding. The superabsorbent material can be any form suitable for absorbent composites, including particles, fibers, sheets, spheres, etc., and combinations thereof. Such superabsorbents are typically available in particle sizes from about twenty micrometers (20 μm) to about one thousand micrometers (1000 μm). The absorbent core 80 may contain 0% (0%) to 100% (100%) of superabsorbent by weight based on the total weight of the absorbent core. In various example embodiments, the absorbent core 80 may have at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% (90%) of superabsorbent material based on the total weight of the absorbent core 80.

[0059] The nonwoven wrapping 84 can be a fibrous nonwoven web made of fine-diameter thermoplastic fibers with specific pore sizes and breathability. While not limited to a specific manufacturing method, meltblown fibrous nonwoven webs have been found to be particularly effective. Regarding the choice of polymer, polyolefin fibers, especially polypropylene-based polymers, have been found to be effective. The fibers can be hydrophilic or hydrophobic, although it is desirable for one or more resulting nonwoven wrappings to be hydrophilic. Therefore, the fibers can be treated to be hydrophilic by using a surfactant.

[0060] The nonwoven wrapping 84 may comprise meltblown, spunbond, spunlace, spunbond-meltblown-spunbond, co-formed, or combinations thereof fibers. The nonwoven wrapping 84 may have a significant amount of tensile strength. For example, the structure of the nonwoven wrapping 84 may comprise an effective amount of elastomeric polymer fibers. Furthermore, the fibers used in the nonwoven wrapping 84 may be continuous or discontinuous. The nonwoven wrapping 84 may be in the form of a membrane, a nonwoven fiber web, or a laminate of two or more substrates or fiber webs. Additionally, the nonwoven wrapping 84 may be textured, open-cell, crepe, neck-stretched, thermally activated, embossed, and micro-strained.

[0061] The nonwoven wrapper 84 may comprise a stretchable, durable, hydrophilic, fluid-permeable substrate. In some example embodiments, the nonwoven wrapper 84 may comprise a coating of nanoparticles having a hydrophilic enhancement amount, wherein such nanoparticles have a particle size of one nanometer (1 nm) to seven hundred and fifty nanometers (750 nm). Examples of suitable nanoparticles include titanium dioxide, layered clay minerals, alumina, silicates, and combinations thereof. Optionally, nonionic surfactants may be incorporated into the nonwoven wrapper 84 to provide additional or enhanced beneficial effects. The nonwoven wrapper 84 may additionally or alternatively comprise materials such as surfactants, ion exchange resin particles, humectants, emollients, fragrances, natural fibers, synthetic fibers, fluid modifiers, odor-controlling additives, detergents, viscosity modifiers, anti-adhesion agents, pH control agents, and combinations thereof.

[0062] Absorbent article 10 may also include surge portion 55 ( Figure 3 This configuration advantageously improves the overall fluid intake rate of the absorber core 80. The surge section 55 is typically less hydrophilic than the absorber core 80 and is configured to collect and temporarily retain fluid surges. This configuration also helps prevent fluid effluent from pooling and accumulating on portions of the absorber core 80.

[0063] Various woven and nonwoven materials can be used to construct the surge portion 55. For example, the surge portion 55 can be a spunbond or meltblown fiber web of polyolefin fibers or a bonded carded fiber web of natural and synthetic fibers. The surge portion 55 can be made of a substantially hydrophobic material and can optionally be treated with a surfactant or otherwise treated to impart a desired level of wettability and hydrophilicity. The surge portion 55 may also include other wettable fibrous materials, such as cotton, rayon, wood pulp, inherently wettable synthetic polymers, hydrophilized or surface-treated polymers, etc. The surge portion 55 can have any desired shape and configuration.

[0064] See now Figure 2 An exemplary absorbent assembly is generally shown at 34, with a portion cut away to show the structure below. The absorbent assembly 34 includes an absorbent core 80, a first nonwoven wrap 84, and a second nonwoven wrap 134.

[0065] The absorbent core 80 may have a front edge 81 and a rear edge 82. The front edge 81 and the rear edge 82 may be generally parallel and opposite in the longitudinal direction 48. The absorbent core 80 may have two side edges 83. The side edges 83 may be opposite in the lateral direction 50. The side edges 83 and / or the front edge 81 and / or the rear edge 82 may be straight, arcuate, or other shapes, or combinations thereof. For example, in Figure 2 In the middle, the rear edge 82 and the front edge 81 are generally straight, while the side edge 83 is generally straight in the front part 22 and the rear part 24, and is arc-shaped in the crotch part 26.

[0066] The first nonwoven wrapping 84 may have a front edge 85 and a rear edge 86. The front edge 85 and the rear edge 86 may be generally parallel and opposite in the longitudinal direction 48. The first nonwoven wrapping 84 may have two side edges 87. The side edges 87 may be opposite in the lateral direction 50. The side edges 87 and / or the front edge 85 and / or the rear edge 86 may be straight, arcuate, or other shapes, or combinations thereof. For example, in Figure 2 In the middle, the rear edge 86, the front edge 85, and the side edge 87 are roughly straight.

[0067] The second nonwoven wrapping 134 may have a front edge 135 and a rear edge 136. The front edge 135 and the rear edge 136 may be generally parallel and opposite in the longitudinal direction 48. The second nonwoven wrapping 134 may have two side edges 137. The side edges 137 may be opposite in the lateral direction 50. The side edges 137 and / or the front edge 135 and / or the rear edge 136 may be straight, arcuate, or other shapes, or combinations thereof.

[0068] The absorbent assembly 34 may have a front extension 90, an intermediate shell 92, and a rear extension 94. The front extension 90 may have a front extension length 91, as measured longitudinally 48 from the front edge 85 of the nonwoven wrapper to the front edge 81 of the absorbent core. In an example embodiment including a second nonwoven wrapper 134, the front extension 90 is measured using either the front edge 85 of the first nonwoven wrapper 84 or the front edge 135 of the second nonwoven wrapper 134, depending on which front edge extends furthest from the core front edge 81. The intermediate shell 92 may have an intermediate shell length 93, as measured longitudinally 48 from the front edge 81 of the absorbent core to the rear edge 82 of the absorbent core. The rear extension 94 may have a rear extension length 95, as measured longitudinally 48 from the rear edge 82 of the absorbent core to the rear edge 86 of the nonwoven wrapper. In an example embodiment including a second nonwoven wrap 134, the rear extension 94 can be measured using either the rear edge 86 of the first nonwoven wrap 84 or the rear edge 136 of the second nonwoven wrap 134, depending on which rear edge extends furthest from the rear edge 82 of the absorbent core. The sum of the front extension length 91, the intermediate shell length 93, and the rear extension length 95 equals the absorbent assembly length 35.

[0069] In various example embodiments, the first nonwoven wrapping 84 may be at least partially bonded to itself, to the second nonwoven wrapping 134, or to both. In various example embodiments, the second nonwoven wrapping 134 may be at least partially bonded to itself, to the first nonwoven wrapping 84, or to both. The first and / or second nonwoven wrapping may be bonded within the front extension 90 and / or the intermediate housing 92 and / or the rear extension 94.

[0070] Bonding in the front extension 90 and / or the rear extension 94 and / or the intermediate housing 92 may be adapted to minimize or eliminate the passage of absorbent core material (especially superabsorbent particles) through them. Bonding in regions 90, 92 and / or 94 may completely seal one or more nonwoven wrappers, thereby preventing any passage of absorbent material. Alternatively or in addition, bonding in regions 90, 92 and / or 94 may partially seal one or more nonwoven wrappers, thereby forming a tortuous path that reduces or eliminates the passage of absorbent material through regions 90, 92 and / or 94. As discussed in more detail below, the front extension 90 and / or the rear extension 94 may be folded to further help reduce or eliminate the passage of absorbent core material.

[0071] The first nonwoven wrapping 84 and / or the second nonwoven wrapping 134 may be bonded to themselves and / or to each other by any suitable mechanism and in any suitable pattern. Suitable bonding mechanisms include pressure bonding, thermal bonding, ultrasonic bonding, adhesive bonding, and combinations thereof.

[0072] In various example embodiments, the length 91 of the front extension can be any suitable length, such as 20 mm to 150 mm (150 mm), 30 mm to 100 mm (100 mm), or 40 mm to 80 mm (80 mm). In various embodiments, the length 91 of the front extension can be less than 200 mm (200 mm), less than 120 mm (120 mm), less than 75 mm (75 mm), or less than 60 mm (60 mm). In various example embodiments, the length 91 of the front extension can be greater than 15 mm (15 mm), greater than 25 mm (25 mm), greater than 40 mm (40 mm), greater than 50 mm (50 mm), greater than 60 mm (60 mm), greater than 70 mm (70 mm), or greater than 100 mm (100 mm).

[0073] In various example embodiments, the length of the front extension 91 may be at least five percent (5%), at least ten percent (10%), at least fifteen percent (15%), at least twenty percent (20%), or at least twenty-five percent (25%) of the length of the absorber component 35. In various example embodiments, the ratio of the length of the absorber component 35 to the length of the front extension 91 may be less than 50:1, less than 25:1, less than 20:1, or less than 15:1. In various example embodiments, the ratio of the length of the absorber component 35 to the length of the front extension 91 may be greater than 3:1, greater than 5:1, greater than 10:1, or greater than 15:1.

[0074] In various embodiments, the intermediate housing length 93 can be any suitable length, such as 70 mm to 700 mm, 200 mm to 500 mm, or 200 mm to 400 mm.

[0075] In various implementation schemes, the length of the intermediate shell 93 is less than 95%, 90%, 85%, 80%, or 75% of the length of the absorption component 35.

[0076] In various example embodiments, the length 95 of the rear extension can be any suitable length, such as 20 mm to 150 mm (150 mm), 30 mm to 100 mm (100 mm), or 40 mm to 80 mm (80 mm). In various embodiments, the length 95 of the rear extension can be less than 200 mm (200 mm), less than 120 mm (120 mm), less than 75 mm (75 mm), or less than 60 mm (60 mm). In various example embodiments, the length 95 of the rear extension can be greater than 15 mm (15 mm), greater than 25 mm (25 mm), greater than 40 mm (40 mm), greater than 50 mm (50 mm), greater than 60 mm (60 mm), greater than 70 mm (70 mm), or greater than 100 mm (100 mm).

[0077] In various example embodiments, the length of the rear extension 95 may be at least five percent (5%), at least ten percent (10%), at least fifteen percent (15%), at least twenty percent (20%), or at least twenty-five percent (25%) of the length of the absorber component 35. In various example embodiments, the ratio of the length of the absorber component 35 to the length of the rear extension 95 may be less than 50:1, less than 25:1, less than 20:1, or less than 15:1. In various example embodiments, the ratio of the length of the absorber component 35 to the length of the rear extension 95 may be greater than 3:1, greater than 5:1, greater than 10:1, or greater than 15:1.

[0078] In various example embodiments, the ratio of the rear extension length 95 to the front extension length 91 can be at least 1:1, at least 1.5:1, at least 2:1, or at least 3:1. When the ratio of the rear extension length 95 to the front extension length 91 is 1:1, the absorbent core 80 is centered within the absorbent assembly 34. When the ratio of the rear extension length 95 to the front extension length 91 is greater than 1:1, the absorbent core 80 is tilted towards the front of the absorbent assembly 34. When the ratio of the rear extension length 95 to the front extension length 91 is less than 1:1, the absorbent core 80 is tilted towards the rear of the absorbent assembly 34. By changing the position of the absorbent core 80 relative to the absorbent assembly 34, the absorbent assembly 34 can remain centered from front to rear within the absorbent article 20, while allowing the absorbent core 80 to be positioned towards the front 22 or rear 24 of the absorbent article 20 as needed.

[0079] Absorption components :

[0080] Now go to Figure 3 The first nonwoven wrapper 84 and / or the second nonwoven wrapper 134 may at least partially encapsulate the absorbent core 80. For example... Figure 3 As shown, the absorbent core 80 may have a surface 98 facing the inner liner and a surface 100 facing the outer cover. As used herein, the term "fully enclosed" means completely enclosed or wrapped within one or more covers. As used herein, the term "at least partially enclosed" means that at least one of the inner liner-facing surface 98 and the outer cover-facing surface 100 of the absorbent core 80 is covered by one or more covers. In example embodiments, the first nonwoven wrap 84 and / or the second nonwoven wrap 134 may fully enclose or at least partially enclose the absorbent core 80 in the manner described in U.S. Patent Publication No. 2007 / 0044903, the disclosure of which is incorporated herein by reference without contradiction. Those skilled in the art will understand that many different variations are possible. In the various example embodiments described herein, the first nonwoven wrap 84 and the second nonwoven wrap 134 are interchangeable.

[0081] The absorbent article 20 includes a body-side liner 30 connected to an outer cover 32 and an absorbent assembly 34 located therebetween. The absorbent assembly 34 includes an absorbent core 80, which is completely encapsulated by a combination of a first nonwoven wrap 84 and a second nonwoven wrap 134. The first nonwoven wrap 84 is folded around the liner-facing surface 98 of the absorbent core 80 and partially folded around the front edge 81 and rear edge 82 of the absorbent core 80. The second nonwoven wrap 134 is folded around the outer cover-facing surface 100 of the absorbent core 80 and partially folded around the front edge 81 and rear edge 82 of the absorbent core 80. The first nonwoven wrap 84 and the second nonwoven wrap 134 overlap at a front extension 90 and a rear extension 94, forming an intermediate shell 92 in which the absorbent core 80 is located.

[0082] In various embodiments, the first nonwoven wrapping 84 and / or the second nonwoven wrapping 134 may be a hydrophobic barrier layer. The hydrophobic barrier layer may comprise a breathable fibrous material, such as a woven or nonwoven fabric, including but not limited to meltblown fiber webs, spunbond fiber webs (e.g., those with a denier of about two (2) or less), bonded carded fiber webs, spunlace fabrics, and other fabrics with similar properties. Suitable polymeric materials for preparing the barrier layer include those capable of forming fiber webs; examples include, but are not limited to, polyamides, polyesters, and polyolefins such as polyethylene and / or polypropylene. In a preferred example aspect, the hydrophobic barrier layer may comprise a meltblown fiber web of polypropylene fibers with a basis weight of about 16 g / m² to about 64 g / m² or 20 g / m² to 40 g / m². The fiber barrier layer may comprise a single sheet or multiple layered sheets collectively having the desired properties.

[0083] As described above and as Figure 3 As shown, the front extension 90 can be folded over itself. In an example embodiment, the front extension 90 can be folded over the intermediate housing 92. For example, the front extension 90 can be folded over the intermediate housing 92 such that the front extension 90 folds onto and contacts the intermediate housing 92 between the front portion 96 and the rear portion 97. Such folding of the front extension 90 can help reduce or eliminate the passage of absorbent core material through the intermediate housing 92 at the front portion 96. For example, folding the front extension 90 can strengthen the bond between the first nonwoven wrap 84 and the second nonwoven wrap 134 at the front portion 96 of the intermediate housing 92. Furthermore, folding the front extension 90 over the intermediate housing 92 can limit or prevent debonding of the first nonwoven wrap 84 and the second nonwoven wrap 134 at the front portion 96 of the intermediate housing 92. Therefore, during the manufacture of absorbent article 20, such as during high-speed folding of absorbent article 20 using a blade folding machine, the fibers and / or superabsorbent material in absorbent core 80 can be retained within intermediate shell 92.

[0084] It should be understood, for example, in addition to Figure 4 and Figure 5 In addition to or as an alternative to the front extension 90 shown, the rear extension 94 may also be folded over itself. In an example embodiment, the rear extension 94 may be folded over the intermediate housing 92. For example, the rear extension 94 may be folded over the intermediate housing 92 such that the rear extension 94 folds over and contacts the intermediate housing 92 between the front portion 96 and the rear portion 97. Such folding of the rear extension 94 can help reduce or eliminate the passage of absorbent core material from the intermediate housing 92 at the rear portion 97. For example, folding the rear extension 94 can strengthen the bond between the first nonwoven wrap 84 and the second nonwoven wrap 134 at the rear portion 97 of the intermediate housing 92. Furthermore, folding the rear extension 94 over the intermediate housing 92 can limit or prevent debonding of the first nonwoven wrap 84 and the second nonwoven wrap 134 at the rear portion 97 of the intermediate housing 92. Therefore, during the manufacture of absorbent article 20, such as during high-speed folding of absorbent article 20 using a blade folding machine, the fibers and / or superabsorbent material in absorbent core 80 can be retained within intermediate shell 92.

[0085] like Figure 3 As shown, the foldable front extension 90 causes the first nonwoven wrapping 84 at the front extension 90 to be folded over and / or in contact with itself. However, it should be understood that in an alternative example embodiment, the foldable front extension 90 causes the second nonwoven wrapping 134 at the front extension 90 to be folded over and / or in contact with itself. Similarly, as Figure 4 and Figure 5 As shown, the foldable rear extension 94 causes the first nonwoven wrapping 84 at the rear extension 94 to be folded over and / or in contact with itself. However, it should be understood that in an alternative example embodiment, the foldable rear extension 94 causes the second nonwoven wrapping 134 at the rear extension 94 to be folded over and / or in contact with itself.

[0086] like Figures 3 to 5As shown, the front extension 90 and / or the rear extension 94 can be folded over the intermediate housing 92, such that the ends of the front extension 90 and / or the rear extension 94 are positioned, for example, along the thickness of the absorbent article 20 perpendicular to the longitudinal direction 48 and the lateral direction 50, between the body-side liner 30 and the absorbent core 80. In other example embodiments, the front extension 90 and / or the rear extension 94 can be folded over the intermediate housing 92, such that the ends of the front extension 90 and / or the rear extension 94 are positioned, for example, along the thickness of the absorbent article 20, between the outer cover 32 and the absorbent core 80. In an example embodiment having a surge portion 55, the front extension 90 and / or the rear extension 94 can be folded over the intermediate housing 92, such that the ends of the front extension 90 and / or the rear extension 94 are positioned, for example, along the thickness of the absorbent article 20, between the surge portion 55 and the absorbent core 80. It should be understood that, in the example implementation, the front extension 90 and / or the rear extension 94 may also be folded without extending rearward over the intermediate housing 92.

[0087] Forming equipment and methods :

[0088] A method for manufacturing absorbent articles (including those described herein) generally includes: forming discrete absorbent cores on a nonwoven wrapping fiber web to form a composite fiber web; bonding the composite fiber web at least partially between the absorbent cores; cutting the composite fiber web between the absorbent cores into discrete absorbent assemblies; folding at least one of the front or rear extensions of each absorbent assembly wrapping; and joining a plurality of absorbent assemblies between a body-side liner and an outer cover. As described herein, other absorbent article components, such as flaps, elastic elements, fasteners, etc., and combinations thereof, may be added.

[0089] As used herein, the term "forming discrete absorbent cores" refers to a method of forming a series of individual, unattached absorbent cores, wherein a first absorbent core is formed and not directly connected to subsequent absorbent cores. Forming discrete absorbent cores contrasts with a method of forming a fiber web in which interconnected absorbent cores are formed, and then cutting it to obtain separate cores. Folding, bonding, and cutting can be performed in any suitable order and can occur substantially simultaneously and / or can be accomplished using multiple units or a single unit adapted to perform multiple functions.

[0090] The methods and apparatus described herein are particularly useful in forming fragile or unstable absorbent cores. For example, the absorbent core formed by the methods and apparatus described herein may consist of a selected mixture of absorbent hydrophilic fibers and superabsorbent particles. In a particular example aspect, the absorbent core may be configured to contain at least about 30 percent (30%) of superabsorbent material by weight. In some example embodiments, the method and apparatus can be used to form absorbent cores containing at least 38 percent (38%), at least 43 percent (43%), at least 50 percent (50%), at least 55 percent (55%), at least 60 percent (60%), at least 65 percent (65%), at least 70 percent (70%), or at least 75 percent (75%) of superabsorbent particles by weight. In some example embodiments, the method and apparatus can be used to form absorbent cores having more than 75 percent (75%) of superabsorbent material by weight.

[0091] As the weight percentage of superabsorbent increases, the integrity of the absorbent core, resulting from fiber entanglement, typically decreases, leading to a more difficult-to-process and inherently more fragile absorbent core. Furthermore, low fiber integrity and high superabsorbent concentration result in more "free" superabsorbent particles being able to move both inside and outside the absorbent core.

[0092] In example embodiments, the fibers of the absorbent core can also be arranged to provide a high-loft, low-density absorbent core. For example, the absorbent core may have an average basis weight of about 300 (300) gsm to about 1,200 (1200) gsm, such as about 400 (400) gsm to about 1,000 (1000) gsm, such as about 500 (500) gsm to about 900 (900) gsm, such as about 600 (600) gsm to about 800 (800) gsm. As another example, the absorbent core may have an average density of about 0.1 (0.1) g / cm³ to about 0.3 (0.3) g / cm³, such as about 0.18 (0.18) g / cm³ to about 0.25 (0.25) g / cm³, such as about 0.2 (0.2) g / cm³ to about 0.22 (0.22) g / cm³. As the average basis weight and / or density of the absorbent core decreases, the integrity of the absorbent core caused by fiber entanglement generally decreases, resulting in a more difficult-to-process and inherently more fragile absorbent core.

[0093] See Figure 6 and Figure 7 An example method and apparatus for forming a discrete absorbent core 80 inserted between a first nonwoven wrapping fiber web 184 and a second nonwoven wrapping fiber web 234 are shown. Figure 7 and Figure 10 Representative examples include Figure 6The method and apparatus shown are followed by a first web supply device, such as a first supply roller 148, for providing a first nonwoven wrapping fiber web 184. A depositor, such as a forming drum 152, deposits a series of discrete absorbent cores 80 onto the first nonwoven wrapping fiber web 184. A second web supply device, such as a second supply roller 154, provides a second nonwoven wrapping fiber web 234 to sandwich the discrete absorbent cores 80 between the first and second nonwoven wrapping fiber webs 184, thereby producing a composite fiber web 147. The various fiber webs move longitudinally as indicated by arrow 188.

[0094] In alternative example embodiments, the method and apparatus may not include a second nonwoven wrapping fiber web and may include only a first nonwoven wrapping fiber web. In other alternative example embodiments, three or more nonwoven wrapping fiber webs may be included in the method and apparatus. In other example embodiments, the first and second nonwoven wrappings are interchangeable, such that the series of discrete absorbent cores are deposited onto the second nonwoven wrapping fiber web and then coupled to the first nonwoven wrapping fiber web.

[0095] The folding device 178 is adapted to fold the first nonwoven wrapping fiber web 184 and / or the second nonwoven wrapping fiber web 234 to at least partially encapsulate the series of discrete absorbent cores 80.

[0096] The composite fiber web 147 is fed to a bonding machine 158, which bonds the composite fiber web 147 at least partially in the attachment area 60 between the absorbent cores 80. Figure 9 The adhesive within the attachment region 60 is adapted to reduce or prevent the movement of superabsorbent material from the absorbent core 80 through the attachment region 60. Generally, the greater the percentage of adhesive in the attachment region 60, the more the movement of superabsorbent material through the attachment region 60 is reduced.

[0097] Such as cutter 127 ( Figure 7 The separator separates the composite fiber web 147 into discontinuous absorbent components 34 along the dividing line 130 in the attachment area 60. Figure 9 ).

[0098] The illustrated example embodiment directly air-forms the fibrous absorbent material onto a first nonwoven wrapper fiber web 184, and includes a hammer mill fiber former 166 and a rotatable forming drum 152. The fiber former 166 breaks down sheets of wood pulp fibers 66 or other suitable fibers and introduces individual fibers into a forming chamber 168. Furthermore, an absorbent supply device, such as an absorbent supply device provided by a supply conduit 170 and nozzle 172, selectively introduces particles of the absorbent material into the forming chamber 168.

[0099] A certain amount of superabsorbent material can be continuously introduced into the forming chamber, or a single amount of superabsorbent material can be intermittently introduced into the forming chamber using a pulse mechanism. The chosen technique will depend on the desired distribution of the superabsorbent throughout the entire area and thickness of the absorbent core. Suitable techniques for introducing particles of superabsorbent material into the forming chamber are described in U.S. Patent Nos. 6,416,697 and 5,028,224, the disclosures of which are incorporated herein by reference without contradiction.

[0100] See now Figure 8 An example forming drum 152 is shown. The forming chamber 168, the first nonwoven wrapper web 184, and the absorbent core 80 are not shown to better illustrate the apparatus below. The forming drum 152 has a peripheral outer surface 190 and includes mechanisms for creating a vacuum therein to draw wood pulp fibers and superabsorbent particles onto the nonwoven wrapper web. The nonwoven wrapper web is carried by the peripheral outer surface 190 of a rotatable forming drum 152 that moves the nonwoven wrapper web through the forming chamber generally in the direction indicated by arrow 189. The peripheral surface 190 of the forming drum 152 includes a permeable forming screen 153. As air is drawn through the forming screen 153 by the vacuum within the forming drum 152, wood pulp fibers and superabsorbent particles are drawn onto the first nonwoven wrapper web to create a series of discrete airflow-formed absorbent cores that are generally regularly spaced along the longitudinal length of the nonwoven wrapper web. Suitable techniques for vacuum forming are described in U.S. Patent Nos. 6,630,096 and 6,630,088, the disclosures of which are incorporated herein by reference without contradiction.

[0101] The forming drum 152 includes a plurality of profile rings 191 engaged to a peripheral outer surface 190. The profile rings 191 are positioned around both sides of the forming drum 152 and extend around its circumference. The profile rings 191 partially obstruct the forming screen 153 and generally guide the superabsorbent and / or fibers to the unobstructed portions of the forming screen 153, thereby forming an absorbent core 80 and defining side edges 83 (e.g., Figure 2 ).

[0102] The forming drum 152 also includes a plurality of cross plates 192 engaged with the peripheral outer surface 190, the profile ring 191, or both. The cross plates 192 extend generally perpendicularly between the profile rings 191. The cross plates 192 partially obstruct the forming screen 153 and generally guide the superabsorbent and / or fibers to the unobstructed portion of the forming screen 153, thereby forming the absorbent core 80 and defining a front edge 81 and a rear edge 82 of the absorbent core. Figure 2 ).

[0103] Multiple cross plates 192 define a first edge 194 and a second edge 195. The distance from the first edge 194 of the first cross plate 198 to the first edge 194 of the second sequential cross plate 199, as measured around the circumference of the forming cylinder 152, defines the forming pitch 196. The forming pitch 196 is equal to the absorption assembly length 35 ( Figure 2 ).

[0104] The distance from the first edge 194 to the second edge 195 of the first cross plate 198, measured around the circumference of the forming cylinder 152, defines the spacing between the absorber cores 80. The spacing between the absorber cores 80 is equal to the length of the attachment area 60, which in turn is equal to the sum of the lengths of the front extension 91 and the rear extension 95.

[0105] A first nonwoven wrapper 134 covers at least a portion of the peripheral outer surface 190 of the forming drum 152. Both the forming drum 152 and the first nonwoven wrapper 134 move in direction 189. A vacuum is drawn through the forming screen 153 and the first nonwoven wrapper 134 in the direction indicated by arrow 156, which in turn draws superabsorbent material and / or fibrous material onto the nonwoven wrapper 184. The contour ring 191 and the cross plate 192 substantially block the vacuum in selected areas of the forming screen 153, thereby substantially preventing the accumulation of absorbent material on the nonwoven wrapper 184, in the areas where the nonwoven wrapper 184 covers the contour ring 191 and / or the cross plate 192. Guiding the absorbent material in this manner results in the formation of a discrete core 80 on the nonwoven wrapper 134 in the unblocked portion of the forming screen 153.

[0106] See you again Figure 6 The fitting mechanism may be located at the outlet end of the forming chamber 168. The shown fitting mechanism includes a fitting rotary drum 174 that is rotatably driven to operably remove excess absorbent material from a single absorbent core 80. The removed material may optionally be recycled back into the forming chamber 168. Suitable fitting methods and apparatus are discussed in U.S. Patent No. 6,627,130, the disclosure of which is incorporated herein by reference without contradiction.

[0107] Upon exiting the position of the inserting drum 174, the nonwoven wrapping fiber web 184 and the series of absorbent cores 80 formed thereon can be removed from the forming drum 152 and placed on the second nonwoven wrapping fiber web 234. At the transfer screen 114, the second nonwoven wrapping fiber web 234 can cooperate with the series of absorbent cores 80 detached from the surface of the forming drum 152 and the associated first nonwoven wrapping fiber web 184 to form a composite fiber web 147. The transfer conveyor 116 can move the composite fiber web 147 from its position near the forming drum 152 into the gap between a pair of compaction rollers 118. The compaction rollers 118 are positioned and elastically held at the selected gap, and operably compress the nonwoven wrapping fiber web 184, the absorbent cores 80, and the second nonwoven wrapping fiber web 234 together. In some example implementations, this compression densifies the absorbent core 80 and can at least partially bond the first nonwoven wrapper fiber web 184 to the second nonwoven wrapper fiber web 234.

[0108] Upon exiting the compaction roller 118, the compaction conveyor 120 transports the compacted composite fiber web 147 to a folding machine, such as, for example, a folding system 178. The folding system 178 may be adapted to wrap a first nonwoven wrapper fiber web 184 and / or a second nonwoven wrapper fiber web 234 (if used), or to wrap both the first nonwoven wrapper fiber web 184 and the second nonwoven wrapper fiber web 234 to at least partially enclose a series of discrete absorbent cores 80 within the composite fiber web 147. After exiting the folding system 178, the composite fiber web 147 may be guided to an bonding module 158, which at least partially bonds the first nonwoven wrapper fiber web 184 and / or the second nonwoven wrapper fiber web 234 in an attachment area 60.

[0109] The illustrated example embodiment includes first and second nonwoven wrapper fiber webs. However, in an alternative example embodiment, the method may include forming discrete absorbent cores on the first nonwoven wrapper fiber web to form a composite fiber web, folding the first nonwoven wrapper fiber web around the discrete absorbent cores, bonding, compacting, and cutting the composite fiber web between the absorbent cores to form discrete absorbent assemblies. In various example embodiments, folding, bonding, and compaction can occur in any order. In various example embodiments, compaction and bonding can occur in a single module adapted to compact the absorbent cores and bond the composite fiber web between the absorbent cores. In various example embodiments, compaction may be omitted. In various example embodiments, folding may be omitted. In various example embodiments, cutting may occur in the same step where the absorbent assemblies are cut and separated.

[0110] Various types of mechanisms can be employed in the bonding machine 158 to form an adhesive bond within the attachment area 60. For example, the attachment area 60 may include an adhesive bond formed by adhesive bonding, thermal bonding, ultrasonic bonding, pressure bonding, or a combination thereof. In the case of adhesive bonding, the adhesive can be applied by patterned extrusion, patterned spraying, patterned printing, or the like. The pattern can be configured to substantially avoid placing excessive amounts of adhesive onto the fibrous hydrophilic material used to construct the absorbent core 80.

[0111] The composite fiber web 147 is conveyed along conveyor 128 to cutter 127. Cutter 127 can be provided by any suitable device, such as, for example, a rotary blade or other suitable cutting mechanism. Cutter 127 cuts along a designated dividing line 130 (…). Figure 9 The composite fiber web 147 is segmented to provide individual absorbent components 34. The absorbent component 34, typically shown, includes an absorbent core 80 encapsulated by a first nonwoven wrap 84 and a second nonwoven wrap 134.

[0112] See now Figure 9 This shows a top view of a portion of the composite fiber web 147 after it has left the bonding module 158. [The portion has been cut off.] Figure 9 The following structure is shown in part. A composite fiber web 147 moves longitudinally 188. The composite web 147 includes a first nonwoven wrapping fiber web 184 facing a second nonwoven wrapping fiber web 234. A series of discrete absorbent cores 80 are disposed between the first nonwoven wrapping fiber web 184 and the second nonwoven wrapping fiber web 234. The first nonwoven wrapping fiber web 184 and the second nonwoven wrapping fiber web 234 are at least partially bonded together in an attachment area 60. A cutting mechanism 127 divides the composite fiber web 147 at a dividing line 130 to form absorbent assemblies 34. The dividing line 130 is aligned to cut between the absorbent cores 80, such that each absorbent assembly 34 includes a front extension 90 and a rear extension 94.

[0113] The dividing line 130 can be located anywhere between the absorbent cores 80. For example, the dividing line 130 can be positioned such that the attachment area 60 is divided in half longitudinally 188. Alternatively, as... Figure 9 As shown, the dividing line 130 can be inclined, so that the attachment area 60 is divided unevenly. In other words, the resulting front extension 90 and rear extension 94 can have different lengths.

[0114] The absorbent assembly 34 includes a first nonwoven wrap 84 and a second nonwoven wrap 134 facing each other. An absorbent core 80 is disposed between the first nonwoven wrap 84 and the second nonwoven wrap 134. The first nonwoven wrap 84 and the second nonwoven wrap 134 are at least partially bonded together in the front extension 90 and the rear extension 94. The bonding can occur in any suitable pattern or concentration. For example, the bonding can include discrete bonding points scattered throughout the front extension 90 and the rear extension 94. In another example, the bonding can include an adhesive that substantially covers the entire front extension 90 and the entire rear extension 94. Those skilled in the art will appreciate that many different patterns, combinations, and coverage areas are possible.

[0115] Once the absorbent assembly 34 is separated, the front extension 90 and / or the rear extension 94 can be folded. For example, the absorbent assembly 34 can be conveyed to a folding machine 140, which folds one or both of the front extension 90 and the rear extension 94. In an example embodiment, the folding machine 140 can fold the front extension 90 and / or the rear extension 94 over the intermediate housing 92. The folding machine 140 may include air nozzles directed at the front extension 90 and / or the rear extension 94, and airflow from the nozzles can fold the front extension 90 and / or the rear extension 94. As another example, the cutter 127 and the conveyor 129 may be positioned such that the front extension 90 and / or the rear extension 94 folds between the cutter 127 and the conveyor 129, for example, due to the speed of the conveyor 129. Other suitable methods and mechanisms for folding the front extension 90 and / or the rear extension 94 are also within the scope of this disclosure.

[0116] As discussed in more detail below, the pre-fold extension 90 and / or post-fold extension 94 can help retain the fluff and / or superabsorbent material in the absorbent core 80 within the intermediate housing 92 during subsequent manufacturing steps. Once folded, the absorbent assembly 34 can then be conveyed along the conveyor 129 to the mounting table 124, where the absorbent assembly 34 is clamped between the fiber web of the body-side liner 131 and the fiber web of the outer cover 132 and operably attached to them. More specifically, the embodiment of the conveyor 129 shown is conventionally constructed to position a series of absorbent assemblies at predetermined, spaced-apart locations along the longitudinal length dimension of the body-side liner fiber web 131. The outer cover fiber web 132 can then be guided by a suitable conveying mechanism to cover the positions of the body-side liner fiber web 131 and the absorbent assembly 34. Thus, the absorbent assembly 34 is inserted between the body-side liner fiber web 131 and the outer cover fiber web 132 to form a series of interconnected absorbent articles 202.

[0117] See Figure 10Conveyor 200 conveys a series of interconnected absorbent articles 202 to cutter 204, such as a rotary blade, which cuts the series of interconnected absorbent articles 202 into individual absorbent articles 20. After cutting, conveyor 206 conveys the articles 20 to folding machine 208, which folds the articles 20 for packaging. Folding machine 208 may be a blade-type folding machine that impacts the articles 20 during folding. Front extension 90 and / or rear extension 94 can help retain the lint and / or superabsorbent material in the absorbent core 80 during folding of the absorbent articles 20 at folding machine 208. For example, front extension 90 and / or rear extension 94 can limit or prevent the soft, low-density discrete absorbent core 80 from leaving or being “squeezed out” from the intermediate shell 92 due to the impact of the blade-type folding machine. Furthermore, the front extension 90 and / or rear extension 94 can form a seal and enhance the adhesion between the first nonwoven wrap 84 and the second nonwoven wrap 134 to limit or prevent material from the absorbent core 80 from leaving the intermediate housing 92 due to the impact of the blade folding machine.

[0118] The folding of the front extension 90 and / or the rear extension 94 can be achieved at high speed. For example, at the cutter 204, the speed of a series of interconnected absorbent articles 202 in the longitudinal direction 188 can be no less than 500 m / min, no less than 800 m / min, no less than 1000 m / min, or no less than 1200 m / min. In some example embodiments, the speed of a series of interconnected absorbent articles 202 in the longitudinal direction 188 at the cutter 204 can be no greater than 5000 m / min.

[0119] These and other modifications and variations of the invention can be practiced by those skilled in the art without departing from the spirit and scope of the invention, which are more specifically set forth in the appended claims. Furthermore, it should be understood that aspects of the various embodiments are interchangeable in whole or in part. Moreover, those skilled in the art will understand that the foregoing description is merely illustrative and is not intended to limit the invention further described in the appended claims.

[0120] Example Implementation Plan

[0121] First example embodiment: An absorbent article comprising: a body-side liner; an outer cover; and an absorbent assembly located between the body-side liner and the outer cover, the absorbent assembly comprising a nonwoven wrapping and an absorbent core, wherein the nonwoven wrapping includes an intermediate shell, a front extension, and a rear extension, the absorbent core being disposed within the intermediate shell of the nonwoven wrapping, the front extension extending from the front of the intermediate shell, the rear extension extending from the rear of the intermediate shell, and wherein one or both of the front extension and the rear extension of the nonwoven wrapping are folded over itself.

[0122] Second example implementation: According to the absorbent article of the first example implementation, wherein the front extension of the nonwoven wrapping is folded over the intermediate shell of the nonwoven wrapping, and the front extension contacts the intermediate shell between the front and rear portions of the intermediate shell.

[0123] Third example implementation: The absorbent article according to the first example implementation or the second example implementation, wherein the rear extension of the nonwoven wrapping is folded over the intermediate shell of the nonwoven wrapping, and the rear extension contacts the intermediate shell between the front and the rear portions of the intermediate shell.

[0124] Fourth example implementation: An absorbent article according to any one of the first to third example implementations, wherein: the nonwoven wrapping includes a first layer and a second layer bonded together to form the nonwoven wrapping; and a front extension of the nonwoven wrapping is folded over an intermediate shell of the nonwoven wrapping, such that the first layer of the nonwoven wrapping at the front extension of the nonwoven wrapping is folded over the first layer of the nonwoven wrapping at the intermediate shell of the nonwoven wrapping.

[0125] Fifth Example Implementation: An absorbent article according to any one of the first to fourth example implementations, wherein: the nonwoven wrapping includes a first layer and a second layer bonded together to form the nonwoven wrapping; and a rear extension of the nonwoven wrapping is folded over an intermediate shell of the nonwoven wrapping, such that the first layer of the nonwoven wrapping at the rear extension of the nonwoven wrapping is folded over the first layer of the nonwoven wrapping at the intermediate shell of the nonwoven wrapping.

[0126] Sixth Example Implementation: An absorbent article according to any one of the first to fifth example implementations, wherein both the front extension and the rear extension of the nonwoven wrapping are folded over the intermediate shell of the nonwoven wrapping.

[0127] Seventh Example Implementation: An absorbent article according to any one of the first to sixth example implementations, wherein: the front and rear portions of the intermediate shell are longitudinally spaced apart; the length of the intermediate shell along the longitudinal direction is not less than three times the length of the front extension along the longitudinal direction and not more than fifty times the length of the front extension along the longitudinal direction; and the length of the intermediate shell is not less than three times the length of the rear extension along the longitudinal direction and not more than fifty times the length of the rear extension along the longitudinal direction.

[0128] Eighth Example Implementation: An absorbent article according to any one of the first to seventh example implementations, wherein: the front and rear portions of the intermediate shell are longitudinally spaced apart; the length of the front extension along the longitudinal direction is not less than 30 mm and not more than 100 mm; and the length of the rear extension along the longitudinal direction is not less than 30 mm and not more than 100 mm.

[0129] Ninth Example Embodiment: An absorbent article according to any one of the first to eighth example embodiments, wherein the absorbent component is spaced apart from the front and rear ends of the body-side liner.

[0130] Tenth Example Embodiment: An absorbent article according to any one of the first to ninth example embodiments, wherein: the body-side liner comprises a liquid-permeable nonwoven fiber web; the outer cover comprises a liquid-impermeable nonwoven fiber web; and the absorbent core comprises one or both of wettable hydrophilic fibers and superabsorbent materials.

[0131] Eleventh Example Implementation: A method for forming an absorbent article, the method comprising: forming a plurality of discrete absorbent cores on a nonwoven wrapping fiber web to form a composite fiber web; cutting the composite fiber web between the discrete absorbent cores to form a plurality of absorbent assemblies, each absorbent assembly including a nonwoven wrapping and an absorbent core, the absorbent core being disposed within an intermediate shell of the nonwoven wrapping in each absorbent assembly; folding at least one of a front extension or a rear extension of each nonwoven wrapping; and joining the plurality of absorbent assemblies between a body-side liner and an outer cover.

[0132] Twelfth Example Implementation: The method according to the eleventh example implementation, wherein the folding includes folding the front extension of each nonwoven package over the intermediate shell of the nonwoven package such that the front extension contacts the intermediate shell.

[0133] Thirteenth Example Implementation: The method according to the eleventh example implementation or the twelfth example implementation, wherein the folding includes folding the rear extension of each nonwoven package over the intermediate shell of the nonwoven package such that the rear extension contacts the intermediate shell.

[0134] Fourteenth Example Implementation: The method according to any one of the eleventh to thirteenth example implementations further includes, before cutting the composite fiber web: folding the composite fiber web to encapsulate the plurality of discrete absorbent cores; and bonding the composite fiber web between the discrete absorbent cores.

[0135] Fifteenth Example Implementation: The method according to any one of the eleventh to fourteenth example implementations, wherein: the length of the intermediate housing along the longitudinal direction is not less than three times the length of the front extension along the longitudinal direction and not more than fifty times the length of the front extension along the longitudinal direction; and the length of the intermediate housing is not less than three times the length of the rear extension along the longitudinal direction and not more than fifty times the length of the rear extension along the longitudinal direction.

[0136] Sixteenth Example Implementation: The method according to any one of the eleventh to fifteenth example implementations, wherein: the length of the front extension along the longitudinal direction is not less than thirty millimeters and not more than one hundred millimeters; and the length of the rear extension along the longitudinal direction is not less than thirty millimeters and not more than one hundred millimeters.

[0137] Seventeenth Example Implementation: The method according to any one of the eleventh to sixteenth example implementations, wherein each absorbent component is spaced apart from the front and rear ends of the body side liner.

[0138] Eighteenth Example Implementation: The method according to any one of the eleventh to seventeenth example implementations, wherein: the body side liner comprises a liquid-permeable nonwoven fiber web; the outer cover comprises a liquid-impermeable nonwoven fiber web; and the absorbent core comprises one or both of wettable hydrophilic fibers and superabsorbent materials.

[0139] Nineteenth Example Implementation: The method according to any one of the eleventh to eighteenth example implementations, wherein folding at least one of the front extension or the rear extension of each nonwoven package includes directing air from a nozzle toward at least one of the front extension or the rear extension of each nonwoven package.

Claims

1. An absorbent article, the absorbent article comprising: Side lining; Outer cover; and An absorbent assembly located between the body-side inner liner and the outer cover, the absorbent assembly comprising a nonwoven wrapping and an absorbent core. The nonwoven wrapping material includes an intermediate shell, a front extension, and a rear extension. The absorbent core is disposed within the intermediate shell of the nonwoven wrapping material. The front extension extends from the front of the intermediate shell, and the rear extension extends from the rear of the intermediate shell. One or both of the front extension and the rear extension of the nonwoven wrapping are folded over itself.

2. The absorbent article of claim 1, wherein the front extension of the nonwoven wrapping is folded over the intermediate shell of the nonwoven wrapping, and the front extension contacts the intermediate shell between the front and rear portions of the intermediate shell.

3. The absorbent article of claim 1, wherein the rear extension of the nonwoven wrapping is folded over the intermediate shell of the nonwoven wrapping, and the rear extension contacts the intermediate shell between the front and rear portions of the intermediate shell.

4. The absorbent article according to claim 1, wherein: The nonwoven wrapping material includes a first layer and a second layer bonded together to form the nonwoven wrapping material; and The front extension of the nonwoven wrapping folds over itself, such that the first layer of the nonwoven wrapping contact portion folds over itself at the front extension of the nonwoven wrapping.

5. The absorbent article according to claim 1, wherein: The nonwoven wrapping material includes a first layer and a second layer bonded together to form the nonwoven wrapping material; and The rear extension of the nonwoven wrapping folds over itself, such that the first layer of the nonwoven wrapping contact portion folds over itself at the rear extension of the nonwoven wrapping.

6. The absorbent article according to claim 1, wherein both the front extension and the rear extension of the nonwoven wrapping are folded over the intermediate shell of the nonwoven wrapping.

7. The absorbent article according to claim 1, wherein: The front and rear portions of the intermediate housing are longitudinally spaced apart; The length of the intermediate housing along the longitudinal direction is not less than three times the length of the front extension along the longitudinal direction and not greater than fifty times the length of the front extension along the longitudinal direction; and The length of the intermediate housing is not less than three times the length of the rear extension along the longitudinal direction and not more than fifty times the length of the rear extension along the longitudinal direction.

8. The absorbent article according to claim 1, wherein: The front and rear portions of the intermediate housing are longitudinally spaced apart; The length of the front extension along the longitudinal direction is not less than 30 mm and not more than 100 mm; and The length of the rear extension along the longitudinal direction is not less than 30 mm and not more than 100 mm.

9. The absorbent article of claim 1, wherein the absorbent assembly is spaced apart from the front and rear ends of the body-side liner.

10. The absorbent article according to claim 1, wherein: The body side lining comprises a liquid-permeable nonwoven fiber web; The outer covering comprises a liquid-impermeable nonwoven fiber web; and The absorbent core comprises one or both of wettable hydrophilic fibers and superabsorbent materials.

11. A method for forming an absorbent article, the method comprising: Multiple discrete absorbent cores are formed on a nonwoven wrapping fiber web to create a composite fiber web; The composite fiber web is cut between the discrete absorbent cores to form a plurality of absorbent assemblies, each absorbent assembly including a nonwoven wrapping and an absorbent core, the absorbent core being disposed within an intermediate shell of the nonwoven wrapping in each absorbent assembly; Fold at least one of the front or rear extensions of each nonwoven wrapping; as well as The plurality of absorbent components are joined between the body-side inner liner and the outer cover.

12. The method of claim 11, wherein the folding comprises folding the front extension of each nonwoven wrapper over the intermediate shell of the nonwoven wrapper such that the front extension contacts the intermediate shell.

13. The method of claim 11, wherein the folding comprises folding the rear extension of each nonwoven wrapping over the intermediate shell of the nonwoven wrapping such that the rear extension contacts the intermediate shell.

14. The method of claim 11, further comprising, before cutting the composite fiber web: Fold the composite fiber web to encapsulate the plurality of discrete absorbent cores; and The composite fiber web is bonded between the discrete absorbent cores.

15. The method according to claim 11, wherein: The longitudinal length of the intermediate housing is not less than three times the longitudinal length of the front extension and not more than fifty times the longitudinal length of the front extension; and The length of the intermediate housing is not less than three times the length of the rear extension along the longitudinal direction and not more than fifty times the length of the rear extension along the longitudinal direction.

16. The method of claim 11, wherein: The longitudinal length of the front extension is not less than 30 mm and not more than 100 mm; and The length of the rear extension along the longitudinal direction is not less than 30 mm and not more than 100 mm.

17. The method of claim 11, wherein each absorbent component is spaced apart from the front and rear ends of the body-side liner.

18. The method according to claim 11, wherein: The body side lining comprises a liquid-permeable nonwoven fiber web; The outer covering comprises a liquid-impermeable nonwoven fiber web; and The absorbent core comprises one or both of wettable hydrophilic fibers and superabsorbent materials.

19. The method of claim 11, wherein folding at least one of the front extension or the rear extension of each nonwoven package comprises directing air from a nozzle toward at least one of the front extension or the rear extension of each nonwoven package.

Images