Absorbent core having a fluid acquisition layer and a fluid storage layer

Abstract

An absorbent article includes a body-side liner, an outer cover, and an absorbent core assembly disposed between the body-side liner and the outer cover. The absorbent core assembly includes a superabsorbent layer having superabsorbent particles. A mixed layer is disposed between the nonwoven layer and the body-side liner. The mixed layer includes superabsorbent particles and cellulose fluff fibers. A nonwoven wrap is disposed about the superabsorbent layer and the mixed layer.

Description

Background Technology

[0001] People rely on disposable absorbent products in their daily lives, including items such as adult incontinence products, bedwetting pants, training pants, and diapers. Many manufacturers are seeking to better meet the needs of users of these products. For example, there is a need to further improve the fit, concealment, and leak protection of many products.

[0002] A key component of many absorbent articles is the absorbent core (such as an absorbent wick) contained within them. These absorbent cores are typically responsible for capturing and retaining bodily fluids, preventing leakage from the absorbent article, and further keeping the fluid away from the wearer's skin, which helps promote skin health. Advances in the structure and performance of absorbent cores to produce thinner products that absorb fluids faster and leak less are an area of ​​continued significant market demand.

[0003] A common approach to improving absorbent cores involves quantitative increases, such as increasing the basis weight of the nonwoven material and / or increasing the application of superabsorbent material (SAM), to improve absorption performance. However, increasing the amount of absorbent can also cause gel blockage and other phenomena, limiting the improvement in absorption capacity. Furthermore, absorbent cores that are predominantly (e.g., 100%) SAM may also have poor initial transient fluid absorption due to the time required for SAM to fully absorb the fluid.

[0004] Thinner absorbent materials that absorb liquid quickly and leak less will be available. Summary of the Invention

[0005] Generally, this disclosure relates to an absorbent article having a composite absorbent core assembly. The composite absorbent core assembly includes a superabsorbent layer and a mixing layer. The superabsorbent layer may be primarily superabsorbent particles, for example, such that the superabsorbent particles are present in the superabsorbent layer at a weight of not less than 93% (93%). The mixing layer may be primarily superabsorbent particles blended with and / or dispersed within cellulose fluff fibers, for example, such that the superabsorbent particles and cellulose fluff fibers are present in the mixing layer at a weight of not less than 93% (93%), wherein the ratio of superabsorbent particles to cellulose fluff fibers is in the range of 5:1 to 2:3 by weight. The mixing layer may be disposed above and / or toward the body side of the absorbent article relative to the superabsorbent layer. The mixing layer may be configured to promote the initial absorption and distribution of liquid body effluent within the composite absorbent core, and the superabsorbent layer may be configured as a reservoir for retaining liquid body effluent. Therefore, for example, the blended layer promotes rapid initial absorption, while the superabsorbent layer limits or prevents backflow from the composite absorbent core to the wearer. In this way, absorbent articles with a composite absorbent core advantageously capture and retain liquid bodily exudates, preventing leakage from the absorbent article and further keeping the liquid away from the wearer's skin, which helps promote skin health. Absorbent articles can also be thinner than conventional absorbent articles, demonstrating both rapid absorption of liquid bodily exudates and limited leakage.

[0006] In one example embodiment, an absorbent article includes a side liner, an outer cover, and an absorbent core assembly disposed between the side liner and the outer cover. The absorbent core assembly includes a superabsorbent layer, a nonwoven layer, a hybrid layer, and a nonwoven wrapping. The superabsorbent layer comprises superabsorbent particles and an adhesive. The adhesive binds the superabsorbent particles together in the superabsorbent layer. The superabsorbent particles are present in the superabsorbent layer at a weight of not less than 95% (95%). The adhesive is present in the superabsorbent layer at a weight of not more than 5% (5%). The nonwoven layer contacts the superabsorbent layer. The hybrid layer comprises superabsorbent particles and cellulose fluff fibers. The hybrid layer is disposed between the nonwoven layer and the side liner. The superabsorbent particles are present in the hybrid layer at a weight of not less than 40% (40%) and not more than 80% (80%). The cellulose fluff fibers are present in the hybrid layer at a weight of not less than 20% (20%) and not more than 60% (60%). A nonwoven wrapping is disposed around a superabsorbent layer and a hybrid layer. The hybrid layer defines multiple channels that extend from the body-facing side of the hybrid layer through the hybrid layer to the outward-facing side of the hybrid layer. These multiple channels are substantially free of superabsorbent particles and cellulose fluff fibers from the hybrid layer.

[0007] In another example embodiment, an absorbent article includes a side liner, an outer cover, and an absorbent core assembly disposed between the side liner and the outer cover. The absorbent core assembly includes a superabsorbent layer, a nonwoven layer, a hybrid layer, and a nonwoven wrapping. The superabsorbent layer contains superabsorbent particles. The superabsorbent particles are present in the superabsorbent layer at a weight of not less than 93% (93%). The hybrid layer contains superabsorbent particles and cellulose fluff fibers. The hybrid layer is disposed between the nonwoven layer and the side liner. The nonwoven wrapping surrounds the superabsorbent layer and the hybrid layer.

[0008] 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

[0009] 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.

[0010] Figure 1 This is a perspective view of absorbent clothing in a closed configuration according to an example aspect of this disclosure.

[0011] Figure 2 It is in an open and flat configuration. Figure 1 Example of a floor plan for absorbing clothing.

[0012] Figure 3 yes Figure 2 Example of absorbent clothing along Figure 2 A schematic cross-sectional view taken from line 3-3.

[0013] Figure 4 This is a cross-sectional view of the absorber core assembly according to an example aspect of this disclosure.

[0014] Figures 5 to 10 It is based on various example implementations of this disclosure. Figure 4 A top plan view of an example absorber core assembly.

[0015] Figure 11 This is a cross-sectional view of the absorber core assembly according to an example aspect of this disclosure.

[0016] Figure 12 This is a cross-sectional view of the absorber core assembly according to an example aspect of this disclosure.

[0017] Figure 13 This is a schematic diagram of a process for forming a core component according to an exemplary aspect of this disclosure.

[0018] Figures 14 to 17This is a graph showing various performance values ​​of a sample absorbent article of the present invention relative to a conventional absorbent article, based on exemplary aspects of this disclosure.

[0019] Figure 18 This is a schematic diagram of another process for forming a core assembly according to an exemplary aspect of this disclosure.

[0020] 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

[0021] This disclosure relates entirely to absorbent articles in which an absorbent core assembly is disposed between a body-side liner and an outer cover. The absorbent core assembly includes a superabsorbent layer, a nonwoven layer, a hybrid layer, and a nonwoven wrapping. The superabsorbent layer contains superabsorbent particles, which are present in the superabsorbent layer at a weight of not less than 93% (93%). An adhesive binds the superabsorbent particles together in the superabsorbent layer. The hybrid layer is disposed between the nonwoven layer and the body-side liner, and the hybrid layer contains superabsorbent particles and cellulose fluff fibers. The superabsorbent particles are present in the hybrid layer at a weight of not less than 40% (40%) and not more than 80% (80%), and the cellulose fluff fibers are present in the hybrid layer at a weight of not less than 20% (20%) and not more than 60% (60%), respectively. The nonwoven wrapping is disposed around the superabsorbent layer and the hybrid layer.

[0022] The blending layer can be positioned and structured to facilitate the initial absorption and distribution of liquid body effluents. For example, the blending layer can rapidly absorb liquid body effluents when it seeps into the side lining. The superabsorbent layer can be positioned and structured to provide a reservoir for retaining liquid body effluents. Thus, the superabsorbent layer can be positioned below the blending layer within the absorbent body, for example, such that the superabsorbent layer is positioned between the blending layer and the outer cover. The superabsorbent layer can provide greater absorption capacity for liquid body effluents, for example, although with a slower absorption rate than the blending layer. Therefore, the absorbent core assembly can provide a multi-layered composite absorbent core that advantageously provides improved initial absorption compared to absorbent cores that primarily contain superabsorbent particles (such as lint-free absorbent cores that are substantially free of cellulose fluff fibers), while also providing desirable rewetting characteristics. The absorbent article can thus advantageously capture and retain liquid body effluents, thereby preventing leakage from the absorbent article and further keeping the liquid away from the wearer's skin, which helps promote skin health. The absorbent article can also be thinner than conventional absorbent articles.

[0023] Additional aspects of this type of absorbent are described in more detail below.

[0024] The following description should be read with reference to the accompanying drawings, in which similar elements in different drawings are numbered the same. The description and drawings (not necessarily drawn to scale) depict exemplary embodiments and are not intended to limit the scope of this disclosure.

[0025] Although some suitable dimensions, ranges and / or values ​​relating to various components, features and / or specifications are disclosed, those skilled in the art inspired by this disclosure will understand that desired dimensions, ranges and / or values ​​may deviate from those explicitly disclosed.

[0026] 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%).

[0027] Each embodiment is provided by way of explanation and is not intended to be limiting. For example, a feature illustrated or described as part of one embodiment or drawing may be used in another embodiment or drawing to produce yet another embodiment. This disclosure is intended to include such modifications and variations.

[0028] Many modifications and variations can 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.

[0029] definition :

[0030] In the context of this specification, each of the following terms or phrases will include one or more of the following meanings. Additional terms are defined elsewhere in the specification.

[0031] The terms "absorbent articles" or "absorbent clothing" herein refer to articles 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, incontinence products, absorbent feminine hygiene products, etc., without departing from the scope of this disclosure.

[0032] The term "airflow web" herein refers to a fiber web manufactured by an airflow web forming process. In an airflow web forming process, small bundles of fibers having a typical length ranging from about three millimeters (3 mm) to about fifty-two millimeters (52 mm) are separated and entrained in an air source, and then deposited onto a shaped screen, typically with the assistance of a vacuum source. The randomly deposited fibers are then bonded together using, for example, a binder component activated by hot air or a latex adhesive. Airflow web forming is taught, for example, in U.S. Patent No. 4,640,810 to Laursen et al., the entire contents of which are incorporated herein by reference for all purposes.

[0033] The term "bonding" 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 bonded to an intermediate component, the two components are considered bonded together. Bonding can be performed via, for example, adhesives, pressure bonding, thermal bonding, ultrasonic bonding, stitching, sewing, and / or welding.

[0034] 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 greater longitudinal strength than transverse strength.

[0035] The terms “cellulose fluff” and “cellulose fluff fiber” refer in this document to blends of cellulose fibers, such as wood pulp fluff. An example of wood pulp fluff can be identified by the trade name NB416, available from Weyerhaeuser Corp., and is a bleached, highly absorbent wood pulp that primarily contains cork fibers.

[0036] The term "co-forming" herein refers to a composite material comprising a mixture or stabilized matrix of thermoplastic fibers and a second non-thermoplastic material. As an example, co-forming materials can be manufactured via a process in which at least one meltblown die is positioned near a chute through which other materials are added to the fiber web during its formation. Such other materials may include, but are not limited to, fibrous organic materials such as wood or non-wood pulp, such as cotton, rayon, recycled paper, pulp fluff, and also include superabsorbent particles, inorganic and / or organic absorbent materials, treated polymer short fibers, etc. Some examples of such co-forming materials are disclosed in the following U.S. Patents: U.S. Patent No. 4,100,324 to Anderson et al., U.S. Patent No. 4,818,464 to Lau, U.S. Patent No. 5,284,703 to Everhart et al., and U.S. Patent No. 5,350,624 to Georger et al., each of which is incorporated herein by reference in its entirety for all purposes.

[0037] The term "connection" refers to the joining, adhesion, bonding, or attachment of two components. Two components are considered connected when they are directly or indirectly connected to each other, such as when each component is directly connected to an intermediate component.

[0038] The term "disposable" refers to articles designed to be discarded after a limited number of uses rather than being washed or otherwise recovered for reuse.

[0039] The terms “set up,” “set on,” and their variations are intended to indicate that a component can be integrated with another component, or that a component can be a separate structure that is bonded to another component, placed together with another component, or placed near another component.

[0040] The terms “elastic,” “elasticized,” and “elastic” refer to the property of a material or composite material that, as a result of this property, tends to return to its original size and shape after the force that caused the deformation has been removed.

[0041] The term "elastomer" refers to a material or composite material that is capable of elongating at least fifty percent (50%) of its relaxed length and recovering at least twenty percent (20%) of its elongation after the applied force is released. Generally preferred is that the elastomer material or composite material is capable of elongating at least fifty percent (50%) of its relaxed length, more preferably at least one hundred percent (100%), and even more preferably at least three hundred percent (300%), and recovering at least fifty percent (50%) of its elongation after the applied force is released.

[0042] The terms "fiber absorbent material" or "absorbent fiber" herein refer to natural fibers, 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 or polyamide fibers), or synthetic fibers composed of non-wettable thermoplastic polymers (e.g., polyolefin fibers that have been hydrophilized in a suitable manner). For example, fibers can be hydrophilized by treatment with surfactants, by treatment with silica, by 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.

[0043] 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.

[0044] The term “gsm” in this article refers to grams per square meter.

[0045] The term “layer” can have a dual meaning when used in the singular, referring to a single element or multiple elements.

[0046] The term “liquid impermeable” in this document refers to a laminate of one or more layers in which liquid bodily effluents such as urine will not pass through the layer or laminate at the point of contact with the liquid in a direction generally perpendicular to the plane of the layer or laminate under normal use conditions.

[0047] The term "liquid-permeable" in this document refers to any material that is permeable to liquids.

[0048] The term "longitudinal" (MD) refers to the length of the fabric in the direction in which it is produced, as opposed to "transverse" (CD), which refers to the width of the fabric in a direction approximately perpendicular to the longitudinal direction.

[0049] The term “component” can have a dual meaning when used in the singular, referring to a single element or multiple elements.

[0050] The terms "nonwoven fabric" or "nonwoven web" as used herein refer to a web of fibers or threads with a structure consisting of individual fibers or threads that are interwoven, but in a manner that is not as clearly discernible as knitted fabrics. Nonwoven fabrics or webs have been formed by a variety of processes, such as meltblown, spunbond, and air-bonded carded webs (also known as BCW and TABCW).

[0051] The term "spunbond fiber web" as used herein refers to a fiber web comprising small-diameter, substantially continuous fibers. Fibers are formed by extruding molten thermoplastic material from multiple fine, typically circular capillaries of a spinneret, followed by rapid reduction of the diameter of the extruded fibers through, for example, traction stretching and / or other well-known spunbonding mechanisms. The preparation of spunbond fiber webs is described and illustrated in the following U.S. patents: for example, 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 No. 3,338,992 to Kinney, U.S. Patent No. 3,341,394 to Kinney, U.S. Patent No. 3,502,763 to Hartman, U.S. Patent No. 3,502,538 to Levy, U.S. Patent No. 3,542,615 to Dobo et al., and U.S. Patent No. 5,382,400 to Pike et al., each of which is incorporated herein by reference in its entirety for all purposes. 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. Spunbond fibers are generally not sticky when deposited onto the collection surface. Spunbond fibers can sometimes have a diameter of less than about forty micrometers (40µm), and are typically between about five micrometers (5µm) and about twenty micrometers (20µm).

[0052] The terms “superabsorbent polymer,” “superabsorbent material,” “SAP,” or “SAM” should be used interchangeably and should refer to polymers capable of absorbing and retaining a very large amount of liquid relative to their own mass. Crosslinkable water-absorbing polymers classified as hydrogels absorb aqueous solutions through hydrogen bonding with water molecules and other polar forces. SAP’s ability to absorb water is based in part on its ionicity (a factor of the ion concentration in the aqueous solution) and the water-affinity of the SAP functional polar groups. SAP is typically made by polymerizing acrylic acid blended with sodium hydroxide in the presence of an initiator to form sodium polyacrylate (sometimes called sodium polyacrylate). Other materials are also used to manufacture superabsorbent polymers, such as polyacrylamide copolymers, ethylene-maleic anhydride copolymers, crosslinked carboxymethyl cellulose, polyvinyl alcohol copolymers, and starch-grafted copolymers of crosslinked polyethylene oxide and polyacrylonitrile. SAP can be present in absorbent clothing in granular or fibrous form, or as a coating or another material or fiber.

[0053] When used with the term "superabsorbent polymer," the terms "particles," "microparticles," etc., refer to the form of discrete units. These units may include flakes, fibers, agglomerates, granules, powders, spheres, pulverized materials, and combinations thereof. Particles may have any desired shape: for example, cubes, rod-shaped polyhedra, spherical or hemispherical shapes, circular or semi-circular shapes, angular shapes, irregular shapes, etc.

[0054] The terms “particulate superabsorbent polymer” and “particulate superabsorbent polymer composition” refer to superabsorbent polymers and superabsorbent polymer compositions in discrete form, wherein the “particulate superabsorbent polymer” and “particulate superabsorbent polymer composition” may have a particle size of less than 1000 μm, or from about 150 μm to about 850 μm.

[0055] The term "polymer" includes, but is not limited to, homopolymers, copolymers such as block, graft, random and alternating copolymers, terpolymers, and their blends and modifications. Furthermore, unless otherwise specifically defined, the term "polymer" shall include all possible configurational isomers of the material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic symmetries.

[0056] Unless otherwise stated herein, the terms “weight percentage (%)” or “weight %” used herein and relating to components of the dry particulate superabsorbent polymer composition shall be interpreted as based on the weight of the dry superabsorbent polymer composition.

[0057] 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.

[0058] These terms may be defined in additional language in the remainder of the instruction manual.

[0059] Absorbent products :

[0060] refer to Figure 1 and Figure 2 The absorbent article or garment 20 extends along a longitudinal direction 23 and a lateral direction 22 perpendicular to the longitudinal direction 23. As used in describing various exemplary embodiments of the garment 20 according to aspects of this disclosure, the terms "longitudinal" and "lateral" have their conventional meanings, as indicated by the central longitudinal axis 24 and the central lateral axis 25. When the garment 20 is fully extended and laid flat, the central longitudinal axis 24 lies in the plane of the garment 20, while the front panel 40 and the back panel 41 are separate, and when the garment 20 is worn, this central longitudinal axis is generally parallel to the vertical plane that divides a standing wearer into a left half and a right half of the body. The central lateral axis 25 lies in the plane of the garment 20 and is generally perpendicular to the central longitudinal axis 24. The garment 20 has a front region 30 defining a front waist edge 32, a rear region 34 defining a rear waist edge 36, and a crotch region 38 longitudinally positioned between the front region 30 and the rear region 34. The crotch area 38 defines two laterally opposed crotch area sides 39. The garment 20 defines the garment length 21 extending from the front waist edge 32 to the back waist edge 36.

[0061] The garment 20 includes a front piece 40 defining a front leg edge 44 longitudinally inwardly spaced from the front waist end edge 32, and first and second laterally opposed front side edges 46, 48. The garment 20 also includes a back piece 41 defining a back leg edge 45 longitudinally inwardly spaced from the back waist end edge 36, and first and second laterally opposed back side edges 47, 49. As used in describing the garment embodiments herein, "longitudinal inward (or inner side)" means in the direction longitudinally toward the central lateral axis 25. Similarly, as used in describing the garment embodiments herein, "lateral inward (or inner side)" means in the direction laterally toward the central longitudinal axis 24. The front piece 40 and the back piece 41 are longitudinally spaced apart. The front piece 40 and the back piece generally comprise an elastic material to conform to the wearer's body.

[0062] A pair of side seams 84 connect the front region 30 to the back region 34, such that the garment 20 defines a waist opening 27 and a pair of leg openings 28. The side seams 84 may be permanent but tearable, such as by adhesive, heat, pressure or ultrasonic bonding, or may be more easily releasable and re-fastened, such as by using mechanical fastening elements.

[0063] The garment 20 may also include at least one front leg elastic member 70 disposed adjacent to the front leg edge 44, and / or at least one rear leg elastic member 75 disposed adjacent to the rear leg edge 45. Such leg elastic members 70 and / or 75 help provide additional elastic support around the leg opening 28 to enhance the fit and leak-proofness of the garment 20. Each leg elastic member 70, 75 may include a single elastic material strip, strand, or thread (or the like), or each leg elastic member may include two, three, or more elastic material strips, strands, or threads (or the like). In certain example embodiments, the rear leg elastic member 75 and / or the front leg elastic member 70 extend laterally across the entire width of the garment. In other example embodiments, such as Figure 1 and Figure 2 In a representative embodiment shown, the hind leg elastic member 75 may include a pair of hind leg elastic members, such as a first hind leg elastic member 76 and a second hind leg elastic member 77 positioned on opposite sides of the absorbent composite material 50. Similarly, the front leg elastic member 70 may include a pair of front leg elastic members, such as a first front leg elastic member 71 and a second front leg elastic member 72 positioned on opposite sides of the absorbent composite material 50. In a preferred example embodiment, such as Figure 1 and Figure 2 In a representative embodiment shown, each hind leg elastic member 75 may include multiple elastomeric strands, and / or each front leg elastic member 70 may include multiple elastomeric strands.

[0064] In certain example embodiments, the absorbent composite material 50 is attached to and located between the front sheet 40 and the rear sheet 41. The absorbent composite material 50 may include a composite structure formed by a liquid-impermeable barrier layer 52 defining a width 53 and a length 51, an absorbent body 54 comprising absorbent material, a liquid-permeable liner 55, and / or a crotch elastic member 56. As used herein, the term "absorbent material" may refer to fibrous absorbent material, superabsorbent material (SAM), or a combination of both. In some example embodiments, the absorbent body 54 may include a layered structure comprising multiple regions of liquid absorbent material (such as fibrous absorbent material and / or SAM). The absorbent body 54 defines a length 61 and a width 63. Reference is made below. Figure 3 Further description of example absorber 54 of this disclosure is presented.

[0065] It should be understood that the exemplary trouser-like garment 20 is merely one possible example of absorbent garments or articles that can be used with the absorbent body 54 described in this disclosure. Figure 1 and Figure 2 The garment 20 shown can be generally described as garment formed using a transverse (CD) manufacturing process. Alternative exemplary garments that can be used with the described absorbent body 54 may include those formed using a longitudinal (MD) manufacturing process. In general, this disclosure is not intended to be limited to the specifically disclosed absorbent garments. Rather, the described absorbent body 54 can be used within any suitable substrate structure for retaining the described absorbent body 54 on a wearer. In a further contemplated example embodiment, the described absorbent body 54 may not be used with any substrate structure at all. Instead, the absorbent body 54 may be configured to allow direct contact with the wearer's body—for example, using a body adhesive disposed on the lateral surface of the absorbent body 54.

[0066] Figure 3 and Figure 4 This is a schematic diagram of a cross-section of an example absorbing body 54 of this disclosure. For example, Figure 3 The main body 54 can be Figure 2 The cross-section of the absorber body 54 in the middle, such as along Figure 2 As observed in line 3-3, any additional layers of clothing 20 are removed. Generally, the absorbent body 54 of this disclosure may comprise a variety of different materials, some of which are layered together to form the body 54.

[0067] like Figure 3 As shown, the absorbent body 54 can be disposed on the inner lining 100 on the side (such as...). Figure 2 The liquid-permeable liner 55 shown is used with the outer cover 110 (such as...). Figure 2 Between the liquid-impermeable barrier layers 52 shown. The body-side liner 100 may be liquid-permeable and may perform well in terms of fluid intake and wicking. Conversely, the outer cover 110 may be liquid-impermeable and may restrict or prevent fluid transmission through it. The absorbent body 54 may extend, for example, along a transverse direction 26 between the body-facing portion 120 and the outward-facing portion 122, which may be perpendicular to the longitudinal direction 23 and the lateral direction 22. The body-facing portion 120 of the absorbent body 54 may be positioned at and / or facing the body-side liner 100. The outward-facing portion 122 of the absorbent body 54 may be positioned at and / or facing the outer cover 110.

[0068] describe Figure 3 and Figure 4A specific example embodiment of the absorbent body 54 shown includes a superabsorbent layer 130 and a hybrid layer 140. The superabsorbent layer 130 and the hybrid layer 140 may be discrete and separated from each other within the absorbent body 54. Thus, the absorbent body 54 may include two (2) or more absorbent material layers with different absorbent material compositions.

[0069] The superabsorbent layer 130 may contain superabsorbent particles. In an example embodiment, the superabsorbent particles may be present in the superabsorbent layer 130 at a rate of not less than 93% (93%) (e.g., not less than 95% (95%), not less than 96% (96%)) by weight of the superabsorbent layer 130. The superabsorbent layer 130 may also contain an adhesive for bonding the superabsorbent particles together within the superabsorbent layer 130. In an example embodiment, the adhesive may be present in the superabsorbent layer 130 at a rate of not more than 7% (7%) (e.g., not more than 5% (5%), e.g., not more than 4% (4%)), not less than 3% (3%) by weight of the superabsorbent layer 130. The adhesive may be applied by spraying directly onto the superabsorbent particles or by spraying onto the nonwoven layer 150.

[0070] As can be seen from the above, the superabsorbent layer 130 may be primarily composed of superabsorbent particles. Furthermore, the superabsorbent layer 130 may be substantially free of cellulose fibers and / or free of fibers. In an example embodiment, the basis weight of the superabsorbent layer 130 may be not less than 90 g / m² (90 gsm) and not more than 350 g / m² (350 gsm). The superabsorbent layer 130 may be constructed by patterning the superabsorbent particles to achieve a smooth fluid distribution.

[0071] The blending layer 140 may comprise superabsorbent particles and cellulose fluff fibers. In an example embodiment, the superabsorbent particles may be present in the blending layer 140 at a weight of less than 40% (40%) and not more than 80% (80%) (e.g., not less than 45% (45%) and not more than 75% (75%), not less than 50% (50%) and not more than 70% (70%), such as about 60% (60%). The cellulose fluff fibers may be present in the blending layer 140 at a weight of less than 20% (20%) and not more than 60% (60%) (e.g., not less than 25% (25%) and not more than 55% (55%), not less than 30% (30%) and not more than 50% (50%), such as about 40% (40%).

[0072] As can be seen from the above, the hybrid layer 140 may comprise both superabsorbent particles and cellulose fluff fibers. For example, the hybrid layer 140 may consist primarily of superabsorbent particles and cellulose fluff fibers. In an example embodiment, the basis weight of the hybrid layer 140 may be not less than 90 g / m² (90 gsm) and not more than 250 g / m² (250 gsm), such as not less than 100 g / m² (100 gsm) and not more than 200 g / m² (200 gsm). In an example embodiment, the hybrid layer 140 may be substantially free of cross-linked cellulose fibers, including crimped, twisted, or coiled cross-linked cellulose fibers. In an example embodiment, the superabsorbent particles in the superabsorbent layer 130 may be of the same type and / or grade as the superabsorbent particles in the hybrid layer 140.

[0073] Figure 3 and Figure 4 The example absorbent body 54 may also include a nonwoven layer 150 and a nonwoven wrapping 160. The nonwoven layer 150 and the nonwoven wrapping 160 may be discrete and separated from each other within the absorbent body 54. Thus, for example, in addition to the superabsorbent layer 130 and the hybrid layer 140, the absorbent body 54 may also include two (2) or more layers of nonwoven material.

[0074] The nonwoven layer 150 may be disposed on and / or in contact with the superabsorbent layer 130. For example, as Figure 3 and Figure 4 As shown, the nonwoven layer 150 may be wrapped around or, in other words, disposed around the superabsorbent layer 130. Furthermore, the nonwoven layer 150 may, for example, surround the superabsorbent layer 130 in a plane perpendicular to the longitudinal direction 23. The nonwoven layer 150 may help limit or prevent the escape of absorbent material (such as superabsorbent particles) from the superabsorbent layer 130.

[0075] In an example implementation, the nonwoven layer 150 can be folded around the superabsorbent layer 130 in a “D-shaped wrap.” Therefore, the opposite ends of the nonwoven layer 150 can overlap to surround the superabsorbent layer 130 with the nonwoven layer 150. The seam of the “D-shaped wrap” nonwoven layer 150 can be located at or near the outward-facing portion 122 of the absorbent body 54, such as… Figure 3 As shown. In other example embodiments, the seam of the "D-shaped wrap" nonwoven layer 150 may be located at or near the body-facing portion 120 of the absorbent body 54. In other example embodiments, the nonwoven layer 150 may be as follows: Figure 11The illustrated "C-shaped wrapping" is folded around the superabsorbent layer 130, wherein the C-shaped portion 132 and the planar portion 134 together wrap the superabsorbent layer 130. The C-shaped portion 132 and the planar portion 134 may be bonded together. In other example embodiments, the nonwoven layer 150 may include two separate layers 136, 138, for example, wherein the superabsorbent layer 130 is sandwiched between the two separate layers 136, 138 along the lateral direction 26. The two separate layers 136, 138 may be bonded to the superabsorbent layer 130 at opposite sides of the superabsorbent layer 130.

[0076] The nonwoven layer 150 can be formed from any suitable material. For example, the nonwoven layer 150 can be liquid-permeable and can perform well in terms of fluid intake and wicking. The nonwoven layer 150 can comprise natural and / or synthetic fibers, such as, but not limited to, polyester, polypropylene, acetate, nylon, polymeric materials, cellulose materials, and combinations thereof. In various examples, the nonwoven layer 150 can be hydrophilic. In various example embodiments, the nonwoven layer 150 can be hydrophobic and can be treated in any manner known in the art to make it hydrophilic.

[0077] Several exemplary suitable materials for the nonwoven layer 150 include tissue materials, spunbond and / or meltblown materials (e.g., spunbond-meltblown materials and spunbond-meltblown-spunbond materials), spunlace materials, and HYDROKNIT. ® The materials (which are commercially available from Kimberly-Clark World Wide, Inc.), air-laid materials, air-bonded carded fiber webs (TABCW), and co-forming materials. The nonwoven layer 150 may have a basis weight in the range of about five g / m² (5 gsm) to about fifty-five g / m² (55 gsm). In other embodiments, other suitable materials and / or materials with a basis weight different from the above range may be used.

[0078] The nonwoven wrapping 160 may be disposed around the superabsorbent layer 130, the hybrid layer 140, and the nonwoven layer 150. For example, as Figure 3 and Figure 4 As shown, the nonwoven wrap 160 may wrap around or in other words surround the superabsorbent layer 130, the hybrid layer 140, and the nonwoven layer 150. Furthermore, the nonwoven wrap 160 may surround the superabsorbent layer 130, the hybrid layer 140, and the nonwoven layer 150, wherein the nonwoven layer 150 is, for example, in a plane perpendicular to the longitudinal direction 23. The nonwoven wrap 160 may help limit or prevent the escape of absorbent material from the absorbent body 54.

[0079] In an example implementation, the nonwoven wrap 160 can be folded around the superabsorbent layer 130, the hybrid layer 140, and the nonwoven layer 150 in a “D-shaped wrap.” Therefore, the opposite ends of the nonwoven wrap 160 can overlap to surround the superabsorbent layer 130, the hybrid layer 140, and the nonwoven layer 150 with the nonwoven wrap 160. The seam of the “D-shaped wrap” nonwoven wrap 160 can be located at or near the outward-facing portion 122 of the absorbent body 54, such as… Figure 3 As shown. In other example embodiments, the seam of the "D-shaped wrapper" nonwoven wrapper 160 may be located at or near the body-facing portion 120 of the absorbent body 54. Thus, for example, in an example embodiment, the seam of the nonwoven wrapper 160 may be located at or near the same portion of the absorbent body 54. Other forms of the nonwoven wrapper 160 are also within the scope of this disclosure, such as "C-shaped wrappers".

[0080] Nonwoven wrapping 160 may include tissue material, spunbond and / or meltblown material (e.g., spunbond-meltblown material or spunbond-meltblown-spunbond material), spunlace material, HYDROKNIT ® Materials, air-laid web materials, air-bonded carded fiber webs (TABCW), and co-forming materials. Preferred materials for the nonwoven wrapping 160 may have a basis weight between about eight g / m² (8 gsm) and about thirty-five g / m² (35 gsm). However, it should be understood that these are merely exemplary materials and basis weights. Generally, any suitable material with any suitable basis weight can be used.

[0081] The absorbent body 54 of this disclosure may comprise absorbent material, i.e., two or more separate absorbent material layers, to provide the absorbent body 54 with beneficial fluid inhalation and storage (e.g., fluid retention) qualities. For example, the absorbent body 54 may include: (1) a superabsorbent layer 130, which is primarily composed of superabsorbent particles; and (2) a hybrid layer 140 having both superabsorbent particles and cellulose fluff fibers.

[0082] In an example implementation, the superabsorbent layer 130 may be heavier than the blending layer 140. For example, the superabsorbent layer 130 may be present in the garment 20 at a weight of less than 25% (25%) and no more than 40% (40%) (e.g., no less than 28% (28%) and no more than 35% (35%)) of the garment 20. The blending layer 140 may be present in the garment 20 at a weight of less than 15% (15%) and no more than 30% (30%) (e.g., no less than 19% (19%) and no more than 25% (25%) of the garment 20. Therefore, for example, the superabsorbent layer 130 may have a greater absorption capacity than the blending layer 140 because of the larger amount of absorbent material in the superabsorbent layer 130 relative to the blending layer 140 and / or because of the composition of the absorbent material in the superabsorbent layer 130 relative to the blending layer 140.

[0083] In an example implementation, the absorbent body 54 may define a thickness TA along the lateral direction 26. The thickness TA of the absorbent body 54 may be smaller than that of a conventional absorbent body. For example, the thickness TA of the absorbent body 54 may not exceed four millimeters (4 cm), such as not exceeding three millimeters (3 mm), such as not exceeding two and a half millimeters (2.5 mm), such as not exceeding two millimeters (2 mm), such as not exceeding one and a half millimeters (1.5 mm), such as not exceeding one and a quarter millimeters (1.25 mm). The superabsorbent layer 130 and the hybrid layer 140 allow for such a thickness of the absorbent body 54 while providing rapid initial absorption and limited backflow.

[0084] As described above, the superabsorbent layer 130 may be disposed below the blending layer 140 within the absorbent body 54. Therefore, the superabsorbent layer 130 may be disposed between the blending layer 140 and the outer cover 110. Compared to the superabsorbent particles and cellulose fluff fibers within the blending layer 140, the superabsorbent particles in the superabsorbent layer 130 provide greater absorption capacity for liquid bodily effluents. However, the superabsorbent particles and cellulose fluff fibers within the blending layer 140 advantageously provide improved initial absorption, for example, relative to an absorbent core with only superabsorbent particles, while also providing desirable rewetting properties. The absorbent body 54 can thus advantageously capture and retain liquid bodily effluents, thereby preventing leakage from the garment 20 and further keeping the liquid away from the wearer's skin, which helps promote skin health. The absorbent body 54 may also be thinner than conventional absorbent articles, for example, along the transverse direction 26.

[0085] like Figure 3 and Figure 4As shown, the absorbent body 54 may further include a collection and / or distribution layer 168 (hereinafter simply referred to as the collection layer 168) disposed between the absorbent body 54 and the body-side liner 100. The collection layer 168 may be attached to the absorbent body 54 at the body-side facing portion 120. In some example embodiments, the collection layer 168 may be attached to the absorbent body 54 by an adhesive. For example, an adhesive layer may be applied to the collection layer 168, and then it may be applied to the absorbent body 54 at the body-side facing portion 120. The collection layer 168 may preferably contain a material similar to those described above with respect to the nonwoven layer 150. For example, the collection layer 168 may preferably contain a tissue material, spunbond and / or meltblown material (e.g., spunbond-meltblown material and spunbond-meltblown-spunbond material), spunlace material, HYDROKNIT ® Materials, air-laid materials, air-bonded carded fiber webs (TABCW), and co-forming materials, and may have a basis weight in the range of about 5 g / m² (5 gsm) to about 55 g / m² (55 gsm). According to some example embodiments, the collection layer 168 may be a tissue, SMS, or spunbond material with a basis weight between about 7 g / m² (7 gsm) and about 20 g / m² (20 gsm), or a co-forming, spunlace, or air-laid material with a basis weight between about 35 g / m² (35 gsm) and about 55 g / m² (55 gsm).

[0086] The collection layer 168 can facilitate the flow of fluid from the body-side liner 100 and the absorbent body 54. For example, the collection layer 168 and the absorbent body 54 can help collect liquid through the clothing 20 and distribute the liquid into the absorbent body 54, thereby accelerating the fluid inhalation time.

[0087] In an example embodiment, garment 20 may further include a bottom integrity sheet 170. The bottom integrity sheet 170 may be disposed between the absorbent body 54 and the outer cover 110. The bottom integrity sheet 170 may help to contain superabsorbent particles within garment 20 and away from the outer cover 52, and provide additional void volume and / or absorption to garment 20 to obtain excellent fluid handling properties. Therefore, ideal materials for use as the bottom integrity sheet 170 include bulk materials and / or absorbent materials, including TABCW materials, spunlace materials, tissue materials, spunbond materials, spunbond meltblown spunbond materials, and co-forming materials. Such materials may have a basis weight between about 10 g / m² (10 gsm) and about 50 g / m² (50 gsm), such as between about 20 g / m² (20 gsm) and about 40 g / m² (40 gsm).

[0088] Additionally, to maintain any absorbent body 54 as an adhesive structure and to help stabilize the absorbent material within the absorbent body 54, the absorbent body 54 may include an additional adhesive. Generally, the adhesive may be applied to different materials of the body 54 to form different adhesive layers. For example, some embodiments may include an adhesive layer located between the nonwoven layer 150 and the superabsorbent layer 130, for example, applied to one or both of the nonwoven layer 150 and the superabsorbent layer 130. Alternatively, example embodiments may include an adhesive layer located between the nonwoven wrap 160 and the nonwoven layer 150 and / or the hybrid layer 140, for example, applied to one or more of the nonwoven wrap 160, the nonwoven layer 150, and the hybrid layer 140.

[0089] Figures 5 to 10 Various example embodiments of the hybrid layer 140 above the superabsorption layer 130 are shown. It will be understood that, although in Figures 5 to 10 Not shown, but a nonwoven layer 150 may be disposed between the mixing layer 140 and the superabsorbent layer 130, and / or the nonwoven layer 150 may wrap around the superabsorbent layer 130. As discussed in more detail below, the mixing layer 140 and the superabsorbent layer 130 may proportionally promote the initial absorption and distribution of liquid body effluents within the absorbent body 54.

[0090] like Figures 5 to 10 As shown, the superabsorbent layer 130 may define a length LS along the longitudinal direction 23, and the superabsorbent layer 130 may define a width WS along the lateral direction 22. The hybrid layer 140 may also define a length LM along the longitudinal direction 23, and the hybrid layer 140 may define a width WM along the lateral direction 22. In the example embodiment, such as Figures 5 to 9 In the embodiments shown, the length LS of the superabsorbent layer 130 can be greater than the length LM of the hybrid layer 140. For example, the length LS of the superabsorbent layer 130 can be no greater than twice (2X) the length LM of the hybrid layer 140. Figure 10 As shown, in the example embodiment, the length LS of the superabsorbent layer 130 may be equal to or approximately equal to the length LM of the hybrid layer 140. In the example embodiment, such as... Figure 5 and Figure 6 In the embodiments shown, the width WS of the superabsorption layer 130 can be greater than the width WM of the mixing layer 140. For example, the width WS of the superabsorption layer 130 can be no greater than twice (2X) the width WM of the mixing layer 140. Figures 7 to 10As shown, in the example embodiment, the width WS of the superabsorbent layer 130 may be equal to or approximately equal to the width WM of the mixing layer 140. This size setting of the superabsorbent layer 130 relative to the mixing layer 140 advantageously allows for the size of the mixing layer 140 to be configured for the initial absorption and distribution of liquid body effluent. Furthermore, this size setting of the superabsorbent layer 130 relative to the mixing layer 140 advantageously allows for the size of the superabsorbent layer 130 to be configured as a reservoir for retaining liquid body effluent, while also allowing for the size of the mixing layer 140 to be configured for initial uptake. The size and / or shape of the mixing layer 140 can be shaped using a forming screen.

[0091] The mixing layer 140 may also be positioned on the superabsorbent layer 130 to facilitate the initial absorption and distribution of liquid body effluents within the absorbent body 54. For example, in Figure 5 and Figure 7 In this configuration, the hybrid layer 140 can be positioned closer to the front edge of the superabsorbent layer 130, which can be positioned adjacent to the front waist edge 32 of the garment 20, such that the hybrid layer 140 is configured for male users. As another example, in... Figure 6 and Figure 8 In this configuration, the hybrid layer 140 can be positioned closer to the rear edge of the superabsorbent layer 130, which can be positioned adjacent to the rear waist edge 36 of the garment 20, such that the hybrid layer 140 is configured for female users. Figure 9 and Figure 10 In the example embodiment shown, the hybrid layer 140 may be disposed concentrically with the superabsorbent layer 130, for example, such that the hybrid layer 140 is configured to be unisex, i.e., for both male and female users.

[0092] refer to Figures 7 to 10 The mixing layer 140 may also define a plurality of channels 142. Channels 142 may extend from the body-facing side 145 of the mixing layer 140. Figure 4The channel 142 extends through the mixing layer 140 to the outward-facing side 146 of the mixing layer 140, for example, along the lateral direction 26. The channel 142 may be substantially free of superabsorbent particles and cellulose fluff fibers of the mixing layer 140. Thus, for example, one open end portion of each channel 142 may be disposed at the nonwoven layer 150, and the opposite open end portion of each channel 142 may be disposed at the nonwoven wrapping 160. The channel 142 may be hollow and configured to guide liquid body effluent through the mixing layer 140 to the underlying superabsorbent layer 130. The channel 142 may thereby improve the performance of the absorbent body 54, in terms of faster first fluid intake time and better reabsorption performance. For example, the channel 142 may provide a direct flow path for the liquid body effluent through the mixing layer 140 to the underlying superabsorbent layer 130, so as to facilitate the rapid transfer of at least a portion of the liquid body effluent to the superabsorbent layer 130.

[0093] Channel 142 can be positioned to facilitate the initial absorption and distribution of liquid body effluent within the absorbent body 54. For example, as... Figures 7 to 10 As shown, channel 142 can be disposed above the middle portion of superabsorbent layer 130. Therefore, channel 142 can facilitate the transfer of liquid body effluent through mixing layer 140 toward the central portion of superabsorbent layer 130. Channel 142 can be oriented to promote the initial absorption and distribution of liquid body effluent within absorbent body 54. For example, as... Figures 7 to 10 As shown, channel 142 can extend in a plane perpendicular to the transverse direction 26 (e.g., along the longitudinal direction 23). As another example, in the plane perpendicular to the transverse direction 26, the common open area of ​​channel 142 can be no less than three square centimeters (3 cm²). 2 And not larger than 20 square centimeters (20cm) 2 Such size and / or shape settings of channel 142 can help collect and distribute liquid through clothing 20 into absorbent body 54, thereby accelerating fluid absorption time.

[0094] The hybrid layer 140 may include a suitable number of channels 142. For example... Figures 7 to 10 As shown, in an example implementation, the hybrid layer 140 may include two channels 142. For example, the hybrid layer 140 may include three, four, five, or more channels 142. In some example implementations, such as... Figure 9 As shown, the mixing layer 140 may include two elongated channels 142 located at the central portion of the mixing layer 140 and, for example, two or more additional channels 144 located at opposite ends of the mixing layer 140 along the longitudinal direction 23.

[0095] Formation method :

[0096] Figure 13This is a schematic diagram of a method 200 for manufacturing an absorbent core (such as the absorbent body 54 of this disclosure). In a first step, core material 201 having a top side and a bottom side may be unwound from a spool including the material forming the core material 201. Core material 201 may correspond to a nonwoven layer 150 and a superabsorbent layer 130, for example, wherein the nonwoven layer 150 wraps around the superabsorbent layer 130, as previously described with respect to the absorbent body 54 of this disclosure. Thus, for example, in an example embodiment, core material 201 may include a superabsorbent layer, wherein the nonwoven layer wraps around the superabsorbent layer. Core material 201 may be formed offline from method 200, wound onto a roll, and the roll of core material 201 may be unwound during method 200. It will be understood that in other example embodiments, core material 201 may be formed online as part of method 200.

[0097] As shown, a mixed absorbent material 202 comprising both superabsorbent particles and cellulose fluff fibers can be applied to a core material 201. The mixed absorbent material 202 may correspond to the aforementioned mixed layer 140. Therefore, for example, the mixed absorbent material 202 can form a separate absorbent material layer on the core material 201. In an example embodiment, the superabsorbent particles and cellulose fluff fibers can be stored in a hopper 215 and distributed through a conduit 216 to a first side of the core material 201 to form the mixed absorbent material 202. In some embodiments, the superabsorbent particles and cellulose fluff fibers are metered, such that a specified amount of superabsorbent particles and cellulose fluff fibers are deposited on the first side of the core material 201.

[0098] Next, the cover material 203 may be unwound from the reel and cover a portion of the core assembly 211, which includes the core material 201 and a mixture of absorbent material 202, forming a complete core assembly 221. In some example embodiments, the cover material 203 may be guided by guide rollers. In some example embodiments, the cover material 203 may correspond to a nonwoven wrap 160.

[0099] Next, process 200 may include embossing the complete core assembly 221 with embossing roller 205. The complete core assembly 221 may also be heat-sealed at roller 206.

[0100] At this point, process 200 may also include cutting the intact core assembly 221 into individual absorbent bodies 54 for absorbent articles (such as garment 20) using a cutter 207. However, method 200 may include additional steps, such as forming absorbent cores (such as those shown). For example, process 200 may also include conveying the formed intact core assembly 221 to a folding machine 208 for folding garment 20, the intact core assembly being a laminate of superabsorbent layer 130, hybrid layer 140, nonwoven layer 150, and nonwoven wrapping 160.

[0101] Figure 18 This is an exemplary schematic diagram of another absorbent structure formation process 300. Process 300 may include unwinding a first fiber web material 310 and moving the first fiber web material 310 along a longitudinal direction 302. Adhesive 330 may be applied to the surface of the first fiber web material 310. An adhesive applicator may pneumatically or by various coating methods or any other suitable application method to apply the adhesive 330 to the first fiber web material 310 in the form of dots, beads, swirls, or any other suitable pattern. However, it should be noted that adhesive 330 may be optional and is not present in other example embodiments. Therefore, in such example embodiments, adhesive 330 is not placed on the first fiber web material 310.

[0102] The first fiber web material 310 may continue longitudinally 302 to a first absorbent material deposition station 320. The first absorbent material deposition station 320 may include a rotating drum 322 having a movable porous forming surface. A vacuum conduit 324 may be located radially inside the forming surface on the rotating drum 322. The vacuum conduit 324 may be connected to a vacuum source (such as an exhaust fan). The first absorbent material deposition station 320 may also include a forming chamber 326 through which the forming surface on the rotating drum 322 is movable. The forming chamber 326 has an inlet at which the forming surface on the rotating drum 322 enters a chamber 326 substantially free of absorbent material, and also has an outlet at which the forming surface on the rotating drum 322 exits a chamber 326 substantially filled with absorbent material. A fiber generator may supply fibrous material into the forming chamber 326. In addition to fibers, other component materials may be delivered into the forming chamber 326. For example, particles or fibers of superabsorbent material may be introduced into the forming chamber 326 via conventional mechanisms such as pipes, channels, diffusers, nozzles, and combinations thereof.

[0103] Vacuum source conduit 324 provides a vacuum pressure relative to the interior of chamber 326. As the forming surface on the rotating drum 322 enters and subsequently traverses the forming chamber 326, fibrous material and superabsorbent material are operably carried or transported onto the first fiber web material 310 by entrained airflow, which is drawn through the forming surface on the rotating drum 322. Thus, the forming chamber 326 can be used to guide and concentrate the entrained air fibers and particles, and to provide a desired velocity distribution in the entrained air fiber and particle flow.

[0104] The porous shaped surface can be defined on the rotating cylinder 322 by a series of shaped elements arranged end-to-end around the periphery of the shaped rotating cylinder 322. Each form can have substantially the same pattern, in which fibrous material and superabsorbent material are deposited. The pattern can correspond to the desired shape of a single absorbent core and can be repeated on the circumference of the rotating cylinder 322.

[0105] The forming surface of the air-supported shaped fiber web 321 (which comprises fibers and particles) on the rotating drum 322 can be moved to the release zone of the first absorbent material deposition station 320. In this release zone, a vacuum transfers the fiber web 321 from the forming surface of the rotating drum 322 onto the first fiber web material 310. Release can be assisted by applying air pressure from inside the rotating drum 322. The first fiber web material 310 receives the shaped fiber web 321 from the forming rotating drum 322 and conveys the fiber web 321 to a collection area or a location for further processing (not shown). A vacuum suction box 332 can be located below the first fiber web material 310 to remove the fiber web 321 from the forming surface of the rotating drum 322. The vacuum box 332 can define an inflation chamber immediately below the portion of the first fiber web material 310 adjacent to the forming surface, such that the vacuum communicates with the fiber web 321 on the rotating drum 322. Alternatively, the fiber web 321 can be removed by weight, by centrifugal force, by mechanical jetting, by positive pressure, or by a combination thereof, or by another suitable method. The removed fiber web comprises a series of interconnected absorbent cores, and each core has a selected surface profile that substantially matches the profile provided by a corresponding portion of a shaped surface, on which each individual pad is formed.

[0106] From the first absorbent material deposition station 320, the first fiber web material 310 and the fiber web 321 thereon can continue along the longitudinal direction 302 to the second absorbent material deposition station 340. At the second absorbent material deposition station 340, the superabsorbent material is mixed with one or more binders, for example in a mixing region, before being deposited onto the second fiber web material 312, and is finally deposited onto the second fiber web material 312.

[0107] Superabsorbent material flows from hopper 342 and through a chute to the second fiber web material 312. Hopper 342 may be a large solid pump or feeder configured to maintain a consistent flow of superabsorbent material through the second absorbent material deposition station 340. The flow rate of superabsorbent material out of hopper 342 may be adjustable, allowing hopper 342 to deliver different amounts of superabsorbent material, resulting in different basis weights of superabsorbent material in the finished absorbent structure 301. Such differences in the basis weight of the superabsorbent material allow the formed absorbent structure 301 to be used for different absorbent end-uses, such as diapers, feminine hygiene products, adult care clothing, bandages, etc.

[0108] The chute can be oriented such that the superabsorbent material exits the chute and falls substantially vertically downwards. The superabsorbent material is preferably fed through the second absorbent material deposition station 340 by gravity rather than any pneumatic force. However, other methods of applying the superabsorbent material from the chute may also be used. Generally, a “sheet” or “flow” of the superabsorbent material can flow from the chute toward the second fiber web material 312.

[0109] As the superabsorbent material falls toward the second fiber web material 312, the adhesive applicator 344 can spray adhesive toward the falling superabsorbent material. The adhesive mixes with the falling superabsorbent material before the mixture of superabsorbent material and adhesive is deposited onto the second fiber web material 312. Two or more adhesive applicators 344 can be used for each stream of superabsorbent material.

[0110] When the second fiber web material 312 passes through the second absorbent material deposition station 340, a deposition mixture 346 of adhesive and superabsorbent material is formed. The adhesive can be used to fix the superabsorbent material to the second fiber web material 312.

[0111] During the deposition of mixture 346, vacuum energy may optionally be applied to the second fiber web material 312. For example, the second fiber web material 312 may be supported by a forming surface (such as a forming belt or forming drum typical in the art). Vacuum energy may be applied to the forming surface such that air is drawn through the forming surface from the side where the second fiber web material 312 is located. Therefore, as mixture 346 falls toward the second fiber web material 312, the second fiber web material 312, along with mixture 346, may be drawn toward the forming surface due to the applied vacuum energy. Such vacuum energy can help control the diffusion of the mixture as it falls toward the second fiber web material 312, thereby contributing to the formation of a relatively more uniform absorption structure 301.

[0112] The third fiber web material 314 may be further applied to the deposition mixture 346. According to some exemplary aspects of this disclosure, a combination of the second fiber web material 312, the deposition mixture 346, and the third fiber web material 314 may be applied to the first fiber web material 310 and the fiber web 321. For example, the combination of the second fiber web material 312, the deposition mixture 346, and the third fiber web material 314 may adhere to the first fiber web material 310 and the fiber web 321 to form the absorbent assembly 316.

[0113] The absorbent assembly 316 can pass through the folding machine 350 to fold the first fiber web material 310 around other portions of the absorbent assembly 316. The absorbent assembly 316 can also pass through one or more nip stations 360 to help compress the assembly together. Generally, the nip stations 360 can apply pressure to a combination of the first fiber web material 310, fiber web 321, second fiber web material 312, deposition mixture 346, and third fiber web material 314 to help further bond the deposition mixture to the fiber web materials 310, 312, and 314.

[0114] After one or more roll gap stations 360, the assembly of absorbent components 316 can be conveyed to a cutting station, where the joined lengths of the first fiber web material 310, fiber web 321, second fiber web material 312, deposition mixture 346, and third fiber web material 314 can be cut into individual absorbent structures 301. These individual absorbent structures 301 can then be assembled into a manufacturing process for producing various absorbent products.

[0115] Figure 13 and Figure 18 For illustrative and discussion purposes, the steps performed in a specific order are described. Those skilled in the art will understand, using the disclosure provided herein, that the steps of any method discussed herein may be adapted, rearranged, expanded, omitted, or modified in various ways without departing from the scope of this disclosure.

[0116] Test methods :

[0117] Inhalation and Reabsorption Test Methods

[0118] The following tests are performed to determine fluid absorption and backflow. This test categorizes the amount of fluid remaining near the diaper surface shortly after absorption and quantifies the amount of fluid not locked in by the absorbent under high pressure after prolonged waiting and multiple absorptions. For successful use, in addition to maintaining fluid to prevent backflow under high pressure, the product must rapidly absorb fluid through the absorbent core layers. Load volume and fluid delivery rate are predetermined based on previous consumer studies of the product. These values ​​may vary depending on the product.

[0119] The equipment and supplies used for testing include: (1) a top-load electronic balance capable of reading 0.001 g; (2) a saline solution, 0.9 + 0.005% (w / w) isotonic saline solution; (3) a countdown timer readable to 0.1 seconds; (4) a rectangular resin glass plate with dimensions of length = 300 mm and width = 100 mm and including an open cylinder located in the center area of ​​the plate, the cylinder having an inner diameter of 38 mm and a height of 125 mm; (5) two weights, each weighing 4 kg; (6) blotting paper, Verigood grade, white, 100 lb, 475 × 600 mm (19 × 24 inches) long stock, 250 sheets / ream, cut into specified sizes of 88 × 300 mm + / - 13 mm (3 5 × 12 inches); (7) polycarbonate sheets (3) cut into 114 mm wide × 432 mm long (4 5 × 17 inches) and weighing 177 g. (675mm thick); (8) a polyethylene funnel, 4 ounce capacity; (9) a low-tack double-sided tape or attachment material to hold the product flat on a surface; (10) a stopwatch readable to 0.1 seconds; and (11) a ruler.

[0120] The samples used for testing were prepared as follows. Based on the product size, the penetration size and rate were determined from the table below.

[0121]

[0122] Next, weigh the product to an accuracy of 0.01 grams and record the weight. If applicable, discard any samples that exceed the weight range specified by the requester.

[0123] For the test setup, ensure the saline solution is at room temperature and has three countdown timers set to 30 seconds, 2 minutes, and 15 minutes.

[0124] For the test, first, place the product on a flat surface and secure the top and bottom to double-sided tape, stretching the product and laying the absorbent core flat. Second, place a plate with an open cylinder on the stretched product, aligning the top edge of the plate with the edge of the absorbent core. Place a funnel on top of the open cylinder in the plate. Third, weigh a sheet of blotting paper on a balance that is readable to three decimal places. Record the weight of the paper. Fourth, according to the instructions in the table below, pour the specified amount of saline solution into the funnel, depending on the size of the product being tested. Start a stopwatch simultaneously. Fifth, once the liquid has completely passed through the cylinder and entered the product (with no liquid on the product surface), immediately stop the stopwatch. Start a timer set to 30 seconds and a timer set to 15 minutes. Sixth, record the absorption time. Seventh, after waiting 30 seconds, remove the plate with the open cylinder. Place the pre-weighed blotting paper on the product and place the polycarbonate plate on top of the product. Eighth, start a timer set to 2 minutes. Ninth, after waiting 2 minutes, remove the polycarbonate plate and blotting paper. Place the plate with the open cylinder back on the product and leave it on the product while continuing to wait. Tenth, weigh the blotting paper to a value accurate to one-thousandth and record the weight. Eleventh, mark the ends of the length along which the fluid extends on the blotting paper. Measure this distance in centimeters along the longitudinal and transverse directions of the blotting paper. Multiply these two distances together to obtain the area of ​​the fluid (diffusion). Record the diffusion. Twelfth, after waiting 15 minutes, place a weight on both sides of the cylinder on the plate. Pour the specified amount of saline solution into the funnel placed in the cylinder according to the table below. Simultaneously start the stopwatch and the countdown timer set to 15 minutes. Thirteenth, once the liquid has completely passed through the cylinder and entered the product (with no liquid on the product surface), immediately stop the stopwatch. Record the second absorption time. Leave the plate with the open cylinder and the weight on the product while continuing to wait. Fourteenth, weigh both sheets of blotting paper and record the weight to three decimal places. Fifteenth, after waiting 15 minutes, remove the weights and the rectangular plate with the cylinder. Place the pre-weighed blotting paper on the product, then place the polycarbonate plate and two weights on top. Start a timer set to 2 minutes. Sixteenth, after waiting 2 minutes, remove the weights, polycarbonate plate, and blotting paper. Immediately weigh the blotting paper on a scale readable to three decimal places and record the weight. Seventeenth, measure the distance along the length of the blotting paper, both longitudinally and laterally, in centimeters. Multiply these two distances together to obtain the area of ​​the fluid (diffusion). Record the diffusion. Eighteenth, remove the product from the surface. Weigh the product and record the weight.

[0125] Example :

[0126] The performance of the sample absorbent product (sample #2) of the present invention was evaluated relative to a conventional absorbent product (sample #1).

[0127] Comparative sample #1 has a lint-free absorbent core. The comparative sample is Huggies. ® Naturemade summer absorbent products.

[0128] Sample #2 of this invention is made of a composite absorbent core having a superabsorbent layer and a mixed layer. The superabsorbent layer is free of fluff and contains approximately 93% (93%) superabsorbent particles by weight of the superabsorbent layer. The mixed layer is primarily superabsorbent particles blended with cellulose fluff fibers, wherein the superabsorbent particles and cellulose fluff fibers are present at approximately 100% (100%) by weight of the mixed layer, and wherein the weight ratio of superabsorbent particles to cellulose fluff fibers is approximately 2:3.

[0129] The first, second, and third initial inhalation values ​​of Sample #1 and Sample #2 of the present invention were evaluated and compared. The results are provided in Table 1 below. Figure 14 In the chart.

[0130] Table 1

[0131]

[0132] As can be seen in Table 1 above, the inhalation time of Sample #2 of the present invention is superior to that of Comparative Sample #1. Furthermore, the initial absorption inhalation time of Sample #2 of the present invention increased from 18.03 seconds to 11.22 seconds, corresponding to an approximately 38% performance improvement in the initial absorption inhalation. The total inhalation time increased from 361.46 seconds to 66.44 seconds, corresponding to an approximately 82% performance improvement. Therefore, Sample #2 of the present invention is superior to Comparative Sample #1 in terms of the first, second, and third inhalations and the total inhalation time.

[0133] The overflow values ​​of comparative sample #1 and sample #2 of the present invention were also evaluated. The results are provided in Table 2 below. Figure 15 In the chart.

[0134] Table 2

[0135]

[0136] As can be seen in Table 2 above, the overflow of sample #2 of the present invention is better than that of comparative sample #1. Furthermore, sample #2 of the present invention did not overflow, while sample #3 of the present invention had an overflow of 6.66 g.

[0137] By placing the hybrid layer on top of the superabsorbent layer in the sample #2 of this invention, the longitudinal and lateral flow of liquid body effluent can be controlled to reduce leakage inhaled via enhanced initial absorption.

[0138] The second high-pressure reabsorption values ​​of comparative sample #1 and sample #2 of the present invention were further evaluated. The results are provided in Table 3 below. Figure 16 In the chart.

[0139] Table 3

[0140]

[0141] As can be seen in Table 3 above, the second high-pressure reflow of sample #2 of the present invention is superior to that of comparative sample #1. Furthermore, the second high-pressure reflow of sample #2 of the present invention increases from 7.44 grams to 2.31 grams, which corresponds to an approximately 69% performance improvement in the second high-pressure reflow.

[0142] The lateral compression of comparative sample #1 and the present invention sample #2 was further evaluated. The results are provided in Table 4 below. Figure 17 In the chart.

[0143] Table 4

[0144]

[0145] As can be seen in Table 4 above, the lateral compression of sample #2 of the present invention is superior to that of comparative sample #1. Furthermore, the lateral compression of sample #2 of the present invention increases from 449.3 g / f to 305.1 g / f, which corresponds to an approximately 32% performance improvement in lateral compression. Therefore, compared to comparative sample #1, the lateral compression of sample #2 of the present invention is significantly more flexible in the groin area after absorption.

[0146] 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.

[0147] Example Implementation Plan

[0148] First Example Implementation: An absorbent article comprising: a body side liner; an outer cover; and an absorbent core assembly disposed between the body side liner and the outer cover, the absorbent core assembly comprising: a superabsorbent layer comprising superabsorbent particles and an adhesive, the adhesive bonding the superabsorbent particles together in the superabsorbent layer, the superabsorbent particles being present in the superabsorbent layer at a weight of not less than 95%, and the adhesive being present in the superabsorbent layer at a weight of not more than 5%; a nonwoven layer in contact with the superabsorbent layer; and a hybrid layer comprising superabsorbent particles and cellulose fibers. The fiber, wherein the blended layer is disposed between the nonwoven layer and the body-side lining, wherein the superabsorbent particles are present in the blended layer in an amount not less than 40% and not more than 80% by weight of the blended layer, and the cellulose fluff fibers are present in the blended layer in an amount not less than 20% and not more than 60% by weight of the blended layer; and a nonwoven wrapping material, wherein the nonwoven wrapping material is disposed around the superabsorbent layer and the blended layer, wherein the blended layer defines a plurality of channels extending from the body-side facing side of the blended layer through the blended layer to the outward-facing side of the blended layer, the plurality of channels being substantially free of the superabsorbent particles and the cellulose fluff fibers of the blended layer.

[0149] Second example implementation: The absorbent article according to the first example implementation, wherein the superabsorbent particles are present in the mixed layer at approximately 70% by weight, and the cellulose fluff fibers are present in the mixed layer at approximately 30% by weight.

[0150] Third example implementation: The absorbent article according to the first example implementation or the second example implementation, wherein the mixed layer exists in the absorbent article at a weight of not less than 10% and not more than 30%.

[0151] Fourth example implementation: The absorbent article according to any one of the first to third example implementations, wherein the superabsorbent layer is present in the absorbent article at a weight of not less than 20% and not more than 40%.

[0152] Fifth example implementation: The absorbent article according to any one of the first to fourth example implementations, wherein the nonwoven layer surrounds the hybrid layer.

[0153] Sixth Example Implementation: An absorbent article according to any one of the first to fifth example implementations, wherein: the absorbent core assembly defines a longitudinal direction, a lateral direction, and a transverse direction that are perpendicular to each other; the hybrid layer is disposed between the nonwoven layer and the body-side lining along the transverse direction; the superabsorbent layer defines a length along the longitudinal direction, the hybrid layer defines a length along the longitudinal direction, the superabsorbent layer defines a width along the lateral direction, the hybrid layer defines a width along the lateral direction, the superabsorbent layer defines a thickness along the transverse direction, and the hybrid layer defines a thickness along the transverse direction; the width of the hybrid layer is not less than the width of the superabsorbent layer; the length of the hybrid layer is not greater than the length of the superabsorbent layer; and the length of the hybrid layer is not greater than the length of the superabsorbent layer.

[0154] Seventh Example Implementation: An absorbent article according to any one of the first to sixth example implementations, wherein the end portion of each of the plurality of channels is disposed at an opening toward the nonwoven layer.

[0155] Eighth Example Implementation: An absorbent article comprising: a body side liner; an outer cover; and an absorbent core assembly disposed between the body side liner and the outer cover, the absorbent core assembly comprising: a superabsorbent layer containing superabsorbent particles, the superabsorbent particles being present in the superabsorbent layer at a weight of not less than 93%; a nonwoven layer; a hybrid layer containing superabsorbent particles and cellulose fluff fibers, the hybrid layer being disposed between the nonwoven layer and the body side liner; and a nonwoven wrapping material surrounding the superabsorbent layer and the hybrid layer.

[0156] Ninth Example Implementation: The absorbent article according to the eighth example implementation, wherein the superabsorbent particles are present in the superabsorbent layer at a weight of not less than 96%.

[0157] Tenth Example Implementation: The absorbent article according to the eighth or ninth example implementation, wherein the superabsorbent particles are present in the mixed layer at a weight of not less than 40% and not more than 80%, and the cellulose fluff fibers are present in the mixed layer at a weight of not less than 20% and not more than 60%, respectively.

[0158] Eleventh Example Implementation: An absorbent article according to any one of the Eighth to Tenth Example Implementations, wherein the superabsorbent particles are present in the mixed layer at approximately 70% by weight, and the cellulose fluff fibers are present in the mixed layer at approximately 30% by weight.

[0159] Twelfth Example Implementation: An absorbent article according to any one of the eighth to eleventh example implementations, wherein the mixed layer is present in the absorbent article at a weight of not less than 10% and not more than 30%.

[0160] Thirteenth Example Implementation: An absorbent article according to any one of the eighth to twelfth example implementations, wherein the mixed layer is present in the absorbent article at a weight of not less than nineteen percent.

[0161] Fourteenth Example Implementation: An absorbent article according to any one of the Eighth to Thirteenth Example Implementations, wherein the superabsorbent layer is present in the absorbent article at a weight of not less than 20% and not more than 40%.

[0162] Fifteenth Example Implementation: An absorbent article according to any one of the eighth to fourteenth example implementations, wherein the superabsorbent layer is present in the absorbent article at a weight of not less than 28 percent.

[0163] Sixteenth Example Implementation: An absorbent article according to any one of the eighth to fifteenth example implementations, wherein the superabsorbent layer is present in the absorbent article at a weight of not less than 20% and not more than 40%.

[0164] Seventeenth Example Implementation: An absorbent article according to any one of the Eighth to Sixteenth Example Implementations, wherein the superabsorbent layer is present in the absorbent article at a weight of not less than 28 percent.

[0165] Eighteenth Example Implementation: The absorbent article according to any one of the eighth to seventeenth example implementations, wherein the superabsorbent layer comprises an adhesive that binds the superabsorbent particles together in the superabsorbent layer.

[0166] Nineteenth Example Implementation: The absorbent article according to any one of the Eighth to Eighteenth Example Implementations, wherein the adhesive is present in the superabsorbent layer at a weight of not more than five percent.

[0167] Twentieth Example Implementation: An absorbent article according to any one of the eighth to nineteenth example implementations, wherein the nonwoven layer surrounds the hybrid layer.

[0168] Twenty-first Example Implementation: An absorbent article according to any one of the eighth to twentieth example implementations, wherein: the absorbent core assembly defines a longitudinal direction, a lateral direction, and a transverse direction that are perpendicular to each other; the hybrid layer is disposed between the nonwoven layer and the body-side lining along the transverse direction; the superabsorbent layer defines a length along the longitudinal direction, the hybrid layer defines a length along the longitudinal direction, the superabsorbent layer defines a width along the lateral direction, and the hybrid layer defines a width along the lateral direction; the width of the hybrid layer is not less than the width of the superabsorbent layer; and the length of the hybrid layer is less than the length of the superabsorbent layer.

[0169] Twenty-second example implementation: The absorbent article according to any one of the eighth to twenty-first example implementations, wherein the mixing layer defines a plurality of channels extending from a body-facing side of the mixing layer through the mixing layer to an outward-facing side of the mixing layer, the plurality of channels being substantially free of the superabsorbent particles and the cellulose fluff fibers of the mixing layer.

[0170] Twenty-third Example Implementation: The absorbent article according to any one of the eighth to twenty-second example implementations, wherein the end portion of each of the plurality of channels is disposed at an opening toward the nonwoven layer.

Claims

1. An absorbent article, the absorbent article comprising: Side lining; Outer cover; and Absorbent core assembly, disposed between the body-side inner liner and the outer cover, the absorbent core assembly comprising: The superabsorbent layer comprises superabsorbent particles and an adhesive, the adhesive binding the superabsorbent particles together in the superabsorbent layer, the superabsorbent particles being present in the superabsorbent layer at a weight of not less than 95%, and the adhesive being present in the superabsorbent layer at a weight of not more than 5%. A nonwoven layer that contacts the superabsorbent layer; A hybrid layer comprising superabsorbent particles and cellulose fluff fibers, disposed between the nonwoven layer and the body lining, wherein the superabsorbent particles constitute not less than 40% and not more than 80% of the hybrid layer by weight, and the cellulose fluff fibers constitute not less than 20% and not more than 60% of the hybrid layer by weight; and A nonwoven wrapping material is disposed around the superabsorbent layer and the hybrid layer. The mixing layer defines a plurality of channels extending from the body-facing side of the mixing layer through the mixing layer to the outward-facing side of the mixing layer, and the plurality of channels are substantially free of the superabsorbent particles and the cellulose fluff fibers of the mixing layer.

2. The absorbent article according to claim 1, wherein, The superabsorbent particles are present in the mixed layer at approximately 70 percent by weight, and the cellulose fluff fibers are present in the mixed layer at approximately 30 percent by weight.

3. The absorbent article according to claim 1, wherein, The mixed layer exists in the absorbent article at a rate of not less than 10% and not more than 30% by weight.

4. The absorbent article according to claim 3, wherein, The superabsorbent layer exists in the absorbent article at a rate of not less than 20% and not more than 40% by weight.

5. The absorbent article according to claim 1, wherein, The nonwoven layer surrounds the hybrid layer.

6. The absorbent article according to claim 1, wherein: The absorber core assembly defines mutually perpendicular longitudinal, lateral, and transverse directions; The hybrid layer is disposed between the nonwoven layer and the body side lining along the transverse direction; The superabsorbent layer defines a length along the longitudinal direction, the hybrid layer defines a length along the longitudinal direction, the superabsorbent layer defines a width along the lateral direction, the hybrid layer defines a width along the lateral direction, the superabsorbent layer defines a thickness along the transverse direction, and the hybrid layer defines a thickness along the transverse direction. The width of the hybrid layer is not less than the width of the superabsorbent layer; The length of the hybrid layer is not greater than the length of the superabsorbent layer; and The length of the hybrid layer is no greater than the length of the superabsorbent layer.

7. The absorbent article according to claim 1, wherein, The end portion of each of the plurality of channels is positioned at an opening facing the nonwoven layer.

8. An absorbent article, said absorbent article comprising: Side lining; Outer cover; and Absorbent core assembly, disposed between the body-side inner liner and the outer cover, the absorbent core assembly comprising: A superabsorption layer comprising superabsorption particles, wherein the superabsorption particles are present in the superabsorption layer at a weight of not less than 93%; Nonwoven layer; A hybrid layer comprising superabsorbent particles and cellulose fluff fibers is disposed between the nonwoven layer and the body-side lining; and A nonwoven wrapping material is disposed around the superabsorbent layer and the hybrid layer.

9. The absorbent article according to claim 8, wherein, The superabsorbent particles, by weight, shall be present in the superabsorbent layer in an amount not less than 96 percent.

10. The absorbent article according to claim 8, wherein, The superabsorbent particles are present in the mixed layer at a rate of not less than 40% and not more than 80% by weight, and the cellulose fluff fibers are present in the mixed layer at a rate of not less than 20% and not more than 60% by weight.

11. The absorbent article according to claim 10, wherein, The superabsorbent particles are present in the mixed layer at approximately 70 percent by weight, and the cellulose fluff fibers are present in the mixed layer at approximately 30 percent by weight.

12. The absorbent article according to claim 8, wherein, The mixed layer exists in the absorbent article at a rate of not less than 10% and not more than 30% by weight.

13. The absorbent article according to claim 12, wherein, The mixed layer is present in the absorbent article at a rate of not less than 19 percent based on the weight of the absorbent article.

14. The absorbent article according to claim 12, wherein, The superabsorbent layer exists in the absorbent article at a rate of not less than 20% and not more than 40% by weight.

15. The absorbent article according to claim 14, wherein, The superabsorbent layer is present in the absorbent article at a rate of not less than 28 percent based on the weight of the absorbent article.

16. The absorbent article according to claim 8, wherein, The superabsorbent layer exists in the absorbent article at a rate of not less than 20% and not more than 40% by weight.

17. The absorbent article according to claim 16, wherein, The superabsorbent layer is present in the absorbent article at a rate of not less than 28 percent based on the weight of the absorbent article.

18. The absorbent article according to claim 8, wherein, The superabsorbent layer includes an adhesive that bonds the superabsorbent particles together in the superabsorbent layer.

19. The absorbent article according to claim 18, wherein, The adhesive is present in the superabsorbent layer at a rate not exceeding five percent by weight.

20. The absorbent article according to claim 8, wherein, The nonwoven layer surrounds the hybrid layer.

21. The absorbent article according to claim 8, wherein: The absorber core assembly defines mutually perpendicular longitudinal, lateral, and transverse directions; The hybrid layer is disposed between the nonwoven layer and the body side lining along the transverse direction; The superabsorbent layer defines a length along the longitudinal direction, the hybrid layer defines a length along the longitudinal direction, the superabsorbent layer defines a width along the lateral direction, and the hybrid layer defines a width along the lateral direction. The width of the hybrid layer is not less than the width of the superabsorbent layer; and The length of the hybrid layer is less than the length of the superabsorbent layer.

22. The absorbent article according to claim 8, wherein, The hybrid layer defines a plurality of channels extending from the body-facing side of the hybrid layer through the hybrid layer to the outward-facing side of the hybrid layer, the plurality of channels being substantially free of the superabsorbent particles and the cellulose fluff fibers of the hybrid layer.

23. The absorbent article according to claim 22, wherein, The end portion of each of the plurality of channels is positioned at an opening facing the nonwoven layer.

Images