Absorbent core with a fluid absorbtion layer and a fluid reservoir layer

Abstract

An absorbent article includes a bodyside liner, an outer cover, and an absorbent core assembly disposed between the bodyside liner and the outer cover. The absorbent core assembly includes a superabsorbent layer with superabsorbent particles. A mixed layer is disposed between a nonwoven layer and the bodyside liner. The mixed layer includes superabsorbent particles and cellulosic fluff fibers. A nonwoven wrap is disposed around the superabsorbent layer and the mixed layer.

Description

[0001] ABSORBENT CORE WITH A FLUID ABSORBTION LAYER AND A FLUID RESERVOIR LAYER

[0002] BACKGROUND

[0003] People rely on disposable absorbent products in their everyday lives, including such articles as adult incontinence products, enuresis pants, training pants, and diapers. Many manufacturers seek to better meet the needs of users of such products. For example, there is a need to further improve fit, discretion, and leakage protection for many products.

[0004] One important component of many absorbent articles are the absorbent bodies, such as absorbent cores, contained in such articles. These absorbent bodies are generally responsible for capturing and retaining liquid bodily exudates, thereby preventing the exudates from leaking out of the absorbent article and further retaining the liquid away from a wearer's skin, which helps to promote skin health. Advances in the structure and performance of absorbent bodies to produce thinner products which uptake liquid more quickly and leak less are a continued important area of market desire.

[0005] One conventional avenue for improving absorbent cores implements quantitative increases, such as increasing basis weight of nonwoven materials and / or increasing application of superabsorbent material (SAM), to improve absorption performance. However, increasing the amount of absorbent can also cause gel blocking and other phenomenon that limit improvement of the absorption capacity. Moreover, absorbent cores with predominantly (e.g., one hundred percent) SAM can also have poor initial instantaneous fluid absorption due to the time required for SAM to fully absorb fluids.

[0006] Thinner absorbent articles with quick liquid uptake and less leakage would be useful.

[0007] SUMMARY

[0008] In general, the present disclosure is directed an absorbent article a hybrid absorbent core assembly. The hybrid absorbent core assembly includes a superabsorbent layer and a mixed layer. The superabsorbent layer may be predominantly superabsorbent particles, e.g., such that the superabsorbent particles are present within the superabsorbent layer at no less than ninety-three percent (93%) percent by weight of the superabsorbent layer. The mixed layer may be predominantly superabsorbent particles blended with and / or dispersed within cellulosic fluff fibers, e.g., such that the superabsorbent particles and the cellulosic fluff fibers are present within the mixed layer at no less than ninety-three percent (93%) by weight of the mixed layer with a ratio of the superabsorbent particles to the cellulosic fluff fibers ranging from 5:1 to 2:3 by weight. The mixed layer may be disposed above and / or towards a bodyside of the absorbent article relative to the superabsorbent layer. The mixed layer may be configured to facilitate initial absorption and distribution of liquid bodily exudates within the hybrid absorbent core, and the superabsorbent layer may be configured as a reservoir for retention of the liquid bodily exudates. Thus, e.g ., the mixed layer may facilitate rapid initial intake while the superabsorbent layer may limit or prevent rewet from the hybrid absorbent core to the wearer. In such a manner, the absorbent article with the hybrid absorbent core may advantageously capture and retain liquid bodily exudates, thereby preventing the exudates from leaking out of the absorbent article and further retaining the liquid away from a wearer's skin, which helps to promote skin health. The absorbent article may also be thinner than conventional absorbent articles while also proving rapid uptake and limited leakage of the liquid bodily exudates.

[0009] In one example embodiment, an absorbent article includes a bodyside liner, an outer cover, and an absorbent core assembly disposed between the bodyside liner and the outer cover. The absorbent core assembly includes a superabsorbent layer, a nonwoven layer, a mixed layer, and a nonwoven wrap. The superabsorbent layer includes superabsorbent particles and an adhesive. The adhesive bonds the superabsorbent particles together in the superabsorbent layer. The superabsorbent particles are present within the superabsorbent layer at no less than ninety-five percent (95%) by weight of the superabsorbent layer. The adhesive is present within the superabsorbent layer at no greater than five percent (5%) by weight of the superabsorbent layer. The nonwoven layer contacts the superabsorbent layer. The mixed layer includes superabsorbent particles and cellulosic fluff fibers. The mixed layer is disposed between the nonwoven layer and the bodyside liner. The superabsorbent particles are present within the mixed layer at no less than forty percent (40%) and no greater than eighty percent (80%) by weight of the mixed layer. The cellulosic fluff fibers are present within the mixed layer at no less than twenty percent (20%) and no greater than sixty percent (60%) by weight of the mixed layer. The nonwoven wrap is disposed around the superabsorbent layer and the mixed layer. The mixed layer defines a plurality of channels that extend through the mixed layer from a bodyside facing side of the mixed layer to an outward facing side of the mixed layer. The plurality of channels are essentially free of the superabsorbent particles and the cellulosic fluff fibers of the mixed layer.

[0010] In another example embodiment, an absorbent article includes a bodyside liner, an outer cover, and an absorbent core assembly disposed between the bodyside liner and the outer cover. The absorbent core assembly includes a superabsorbent layer, a nonwoven layer, a mixed layer, and a nonwoven wrap. The superabsorbent layer includes superabsorbent particles. The superabsorbent particles are present within the superabsorbent layer at no less than ninety-three (93%) percent by weight of the superabsorbent layer. The mixed layer includes superabsorbent particles and cellulosic fluff fibers. The mixed layer is disposed between the nonwoven layer and the bodyside liner. The nonwoven wrap is disposed around the superabsorbent layer and the mixed layer.

[0011] These and other features, aspects and advantages of the present disclosure will become better understood with reference to the following description and 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.

[0012] BRIEF DESCRIPTION OF THE DRAWINGS

[0013] A full and enabling disclosure of the present disclosure, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

[0014] FIG. 1 is a perspective view of an absorbent garment in a closed configuration, according to example aspects of the present disclosure.

[0015] FIG. 2 is a plan view of the example absorbent garment of FIG. 1 in an open and laid flat configuration.

[0016] FIG. 3 is a schematic, section view of the example absorbent garment of FIG. 2 taken along the 3-3 line of FIG. 2.

[0017] FIG. 4 is a section view of an absorbent core assembly according to example aspects of the present disclosure.

[0018] FIGS. 5 through 10 are top plan views of the example absorbent core assembly of FIG. 4 according to various example embodiments of the present disclosure.

[0019] FIG. 11 is a section view of an absorbent core assembly according to example aspects of the present disclosure.

[0020] FIG. 12 is a section view of an absorbent core assembly according to example aspects of the present disclosure.

[0021] FIG. 13 is a schematic view of a process for forming core assemblies according to example aspects of the present disclosure.

[0022] FIGS. 14 through 17 are charts of various performance values for a sample inventive absorbent article relative to a comparative conventional absorbent article according example aspects of the present disclosure.

[0023] FIG. 18 is a schematic view of another process for forming core assemblies according to example aspects of the present disclosure. Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

[0024] DETAILED DESCRIPTION

[0025] The present disclosure is generally directed an absorbent article with an absorbent core assembly disposed between a bodyside liner and an outer cover. The absorbent core assembly includes a superabsorbent layer, a nonwoven layer, a mixed layer, and a nonwoven wrap. The superabsorbent layer includes superabsorbent particles, which may be present within the superabsorbent layer at no less than ninety-three percent (93%) by weight of the superabsorbent layer. An adhesive may bond the superabsorbent particles together in the superabsorbent layer. The mixed layer is disposed between the nonwoven layer and the bodyside liner, and the mixed layer includes superabsorbent particles and cellulosic fluff fibers. The superabsorbent particles may be present within the mixed layer at no less than forty percent (40%) and no greater than eighty percent (80%) by weight of the mixed layer, and the cellulosic fluff fibers may be present within the mixed layer at no less than twenty percent (20%) and no greater than sixty percent (60%) by weight of the mixed layer. The nonwoven wrap is disposed around the superabsorbent layer and the mixed layer.

[0026] The mixed layer may be positioned and structured to facilitate initial absorption and distribution of liquid bodily exudates. For instance, the mixed layer may rapidly absorb liquid bodily exudates upon insult at the bodyside liner. The superabsorbent layer may be positioned and structured to provide a reservoir for retention of the liquid bodily exudates. Thus, the superabsorbent layer may be disposed below the mixed layer within the absorbent body, e.g . , such that the superabsorbent layer is disposed between the mixed layer and the outer cover. The superabsorbent layer may provide greater absorption capacity for the liquid bodily exudates, e.g., despite have a slower absorption rate than the mixed layer. Thus, the absorbent core assembly may provide a multilayer, hybrid absorbent core, which can advantageously provide improved initial intake relative to absorbent core with predominantly superabsorbent particles, such as fluff free absorbent cores that are essentially free of cellulosic fluff fibers, while also providing desirable rewet characteristics. The absorbent article may thereby advantageously capture and retain liquid bodily exudates, thereby preventing the exudates from leaking out of the absorbent article and further retaining the liquid away from a wearer's skin, which helps to promote skin health. The absorbent article may also be thinner than conventional absorbent articles.

[0027] Additional aspects of such absorbent bodies are described in more detail below. The following description should be read with reference to the drawings in which similar elements in different drawings are numbered the same. The description and the drawings, which are not necessarily to scale, depict illustrative embodiments and are not intended to limit the scope of the disclosure.

[0028] Although some suitable dimensions, ranges and / or values pertaining to various components, features and / or specifications are disclosed, one of skill in the art, incited by the present disclosure, would understand desired dimensions, ranges and / or values may deviate from those expressly disclosed.

[0029] When introducing elements of the present disclosure or the preferred embodiment(s) thereof, the articles “a", "an”, "the” and “said” are intended to mean that there are one or more of the elements. As used herein, the terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e. , “A or B” is intended to mean “A or B or both”). Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. For example, the approximating language may refer to being within a ten percent (10%) margin.

[0030] Each example is provided by way of explanation and is not meant as a limitation. For example, features illustrated or described as part of one embodiment or figure can be used on another embodiment or figure to yield yet another embodiment. It is intended that the present disclosure include such modifications and variations.

[0031] Many modifications and variations of the present disclosure can be made without departing from the spirit and scope thereof. Therefore, the exemplary embodiments described above should not be used to limit the scope of the invention.

[0032] Definitions:

[0033] Within the context of this specification, each term or phrase below will include the following meaning or meanings. Additional terms are defined elsewhere in the specification.

[0034] The term “absorbent article” or “absorbent garment” refers herein to an article which may be placed against or in proximity to the body (i.e., contiguous with the body) of the wearer to absorb and contain various liquid, solid, and semi-solid exudates discharged from the body. Such absorbent articles, as described herein, are intended to be discarded after a limited period of use instead of being laundered or otherwise restored for reuse. It is to be understood that the present disclosure is applicable to various disposable absorbent articles, including, but not limited to, diapers, diaper pants, training pants, youth pants, swim pants, incontinence products, absorbent feminine care products, and the like without departing from the scope of the present disclosure.

[0035] The term “airlaid” refers herein to a web manufactured by an airlaying process. In the airlaying process, bundles of small fibers having typical lengths ranging from about three millimeters (3 mm) to about fifty-two millimeters (52 mm) are separated and entrained in an air supply and then deposited onto a forming screen, usually with the assistance of a vacuum supply. The randomly deposited fibers are then bonded to one another using, for example, hot air to activate a binder component or a latex adhesive. Airlaying is taught in, for example, U.S. Patent No. 4,640,810 to Laursen, et al., which is incorporated herein in its entirety by reference thereto for all purposes.

[0036] The term “bonded’’ refers to the joining, adhering, connecting, attaching, or the like, of two elements. Two elements will be considered bonded together when they are joined, adhered, connected, attached, or the like, directly to one another or indirectly to one another, such as when bonded to an intermediate element. The bonding can occur via, for example, adhesive, pressure bonding, thermal bonding, ultrasonic bonding, stitching, suturing, and / or welding.

[0037] The term “carded web” refers herein to a web containing natural or synthetic staple fibers typically having fiber lengths less than about one hundred millimeters (100 mm). Bales of staple fibers can undergo an opening process to separate the fibers that are then sent to a carding process that separates and combs the fibers to align them in the machine direction after which the fibers are deposited onto a moving wire for further processing. Such webs are usually subjected to some type of bonding process, such as thermal bonding using heat and / or pressure. In addition to or in lieu thereof, the fibers can be subject to adhesive processes to bind the fibers together, such as by the use of powder adhesives. The carded web can be subjected to fluid entangling, such as hydroentangling, to further intertwine the fibers and thereby improve the integrity of the carded web. Carded webs, due to the fiber alignment in the machine direction, once bonded, will typically have more machine direction strength than cross machine direction strength.

[0038] The term “cellulosic fluff' and “cellulosic fluff fibers” refers herein to a blend of cellulosic fibers, such as wood pulp fluff. An example of wood pulp fluff can be identified with the trade designation NB416, available from Weyerhaeuser Corp., and is a bleached, highly absorbent wood pulp containing primarily soft wood fibers.

[0039] The term “coform” refers herein to composite materials comprising a mixture or stabilized matrix of thermoplastic fibers and a second non-thermoplastic material. As an example, coform materials may be made by a process in which at least one meltblown die head is arranged near a chute through which other materials are added to the web while it is forming. Such other materials may include, but are not limited to, fibrous organic materials such as woody or non-woody pulp such as cotton, rayon, recycled paper, pulp fluff, and also superabsorbent particles, inorganic and / or organic absorbent materials, treated polymeric staple fibers and so forth. Some examples of such coform materials are disclosed in U.S. Patent Nos. 4,100,324 to Anderson, et al., 4,818,464 to Lau, 5,284,703 to Everhart, et al., and 5,350,624 to Georger, et al., each of which are incorporated herein in their entirety by reference thereto for all purposes.

[0040] The term "connected” refers to the joining, adhering, bonding, attaching, or the like, of two elements. Two elements will be considered to be connected together when they are connected directly to one another or indirectly to one another, such as when each is directly connected to intermediate elements.

[0041] The term “disposable” refers to articles which are designed to be discarded after a limited use rather than being laundered or otherwise restored for reuse.

[0042] The term “disposed,” “disposed on,” and variations thereof are intended to mean that one element can be integral with another element, or that one element can be a separate structure bonded to or placed with or placed near another element.

[0043] The term “elastic,” “el asticized” and “elasticity” mean that property of a material or composite by virtue of which it tends to recover its original size and shape after removal of a force causing a deformation.

[0044] The term “elastomeric” refers to a material or composite which can be elongated by at least fifty percent (50%) of its relaxed length and which will recover, upon release of the applied force, at least twenty percent (20%) of its elongation. It is generally preferred that the elastomeric material or composite be capable of being elongated by at least fifty percent (50%), more preferably by at least one hundred percent (100%), and still more preferably by at least three hundred percent (300%) of its relaxed length and recover, upon release of an applied force, at least fifty percent (50%) of its elongation.

[0045] The term “fibrous absorbent material” or “absorbent fibers” refers herein to natural fibers, cellulosic fibers, synthetic fibers composed of cellulose or cellulose derivatives, such as rayon fibers; inorganic fibers composed of an inherently wettable material, such as glass fibers; synthetic fibers made from inherently wettable thermoplastic polymers, such as particular polyester or polyamide fibers, or composed of nonwettable thermoplastic polymers, such as polyolefin fibers which have been hydrophilized by suitable means. The fibers may be hydrophilized, for example, by treatment with a surfactant, treatment with silica, treatment with a material which has a suitable hydrophilic moiety and is not readily removed from the fiber, or by sheathing the nonwettable, hydrophobic fiber with a hydrophilic polymer during or after formation of the fiber.

[0046] The term “film" refers herein to a thermoplastic film made using an extrusion and / or forming process, such as a cast film or blown film extrusion process. The term includes apertured films, slit films, and other porous films that constitute liquid transfer films, as well as films that do not transfer fluids, such as, but not limited to, barrier films, filled films, breathable films, and oriented films.

[0047] The term “gsm” refers herein to grams per square meter.

[0048] The term “layer” when used in the singular can have the dual meaning of a single element or a plurality of elements.

[0049] The term “liquid impermeable” refers herein to a layer or multi-layer laminate in which liquid body exudates, such as urine, will not pass through the layer or laminate, under ordinary use conditions, in a direction generally perpendicular to the plane of the layer or laminate at the point of liquid contact.

[0050] The term “liquid permeable” refers herein to any material that is not liquid impermeable.

[0051] The term “machine direction” (MD) refers to the length of a fabric in the direction in which it is produced, as opposed to a “cross-machine direction” (CD) which refers to the width of a fabric in a direction generally perpendicular to the machine direction.

[0052] The term “member” when used in the singular can have the dual meaning of a single element or a plurality of elements.

[0053] The term “nonwoven fabric” or “nonwoven web” refers herein to a web having a structure of individual fibers or threads which are interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven fabrics or webs have been formed from many processes such as, for example, meltblowing processes, spunbonding processes, through-air bonded carded web (also known as BCW and TABCW) processes, etc.

[0054] The term “spunbond web” refers herein to a web containing small diameter substantially continuous fibers. The fibers are formed by extruding a molten thermoplastic material from a plurality of fine, usually circular, capillaries of a spinneret with the diameter of the extruded fibers then being rapidly reduced as by, for example, eductive drawing and / or other well-known spunbonding mechanisms. The production of spunbond webs is described and illustrated, for example, in U.S. Patent Nos. 4,340,563 to Appel, et al., 3,692,618 to Dorschner, et al., 3,802,817 to Matsuki, et al., 3,338,992 to Kinney, 3,341 ,394 to Kinney, 3,502,763 to Hartman, 3,502,538 to Levy, 3,542,615 to Dobo, et al., and 5,382,400 to Pike, et al., which are each incorporated herein in their entirety by reference thereto for all purposes. Spunbond fibers are generally continuous and often have average deniers larger than about 0.3, and in an embodiment, between about 0.6, 5 and 10 and about 15, 20 and 40. Spunbond fibers are generally not tacky when they are deposited onto a collecting surface. Spunbond fibers may sometimes have diameters less than about forty microns (40 pm), and often between about five microns (5 m), to about twenty microns (20 pm).

[0055] The term “superabsorbent polymer,” “superabsorbent material”, “SAP”, or “SAM” shall be used interchangeably and shall refer to polymers that can absorb and retain extremely large amounts of a liquid relative to their own mass. Water absorbing polymers, which are classified as hydrogels, which can be cross-linked, absorb aqueous solutions through hydrogen bonding and other polar forces with water molecules. A SAP's ability to absorb water is based in par on iconicity (a factor of the ionic concentration of the aqueous solution), and the SAP functional polar groups that have an affinity for water. SAP are typically made from the polymerization of acrylic acid blended with sodium hydroxide I the presence of an initiator to form a poly-acrylic acid sodium salt (sometimes referred to as sodium polyacrylate). Other materials are also used to make a superabsorbent polymer, such as polyacrylamide copolymer, ethylene maleic anhydride copolymer, cross-linked carboxymethylcellulose, polyvinyl alcohol copolymers, cross-linked polyethylene oxide, and starch grafted copolymer of polyacrylonitrile. SAP may be present in absorbent garments in particle or fibrous form or as a coating or another material or fiber.

[0056] The term “particle," “particulate,” and the like, when used with the term “superabsorbent polymer,” refer to the form of discrete units. The units can comprise flakes, fibers, agglomerates, granules, powders, spheres, pulverized materials, or the like, as well as combinations thereof. The particles can have any desired shape: for example, cubic, rod like polyhedral, spherical or semi- spherical, rounded or semi-rounded, angular, irregular, et cetera.

[0057] The term “particulate superabsorbent polymer" and “particulate superabsorbent polymer composition” refer to the form of superabsorbent polymer and superabsorbent polymer compositions in discrete form, wherein the “particulate superabsorbent polymer” and “particulate superabsorbent polymer compositions” may have a particle size of less than 1000pm, or from about 150pm to about 850 pm.

[0058] The term “polymer" includes, but is not limited to, homopolymers, copolymers, for example, block, graft, random, and alternating copolymers, terpolymers, etc., and blends and modifications thereof. Furthermore, unless otherwise specifically limited, 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. The term “percent (%) by weight” or “%wt” as used herein and referring to components of the dry particulate superabsorbent polymer composition, is to be interpreted as based on the weight of the dry superabsorbent polymer composition, unless otherwise specified herein.

[0059] The term “superabsorbent” refers herein to a water-swellable, water-insoluble organic or inorganic material capable, under the most favorable conditions, of absorbing at least about fifteen (15) times its weight and, in an aspect, at least about thirty (30) times its weight, in an aqueous solution containing 0.9 weight percent sodium chloride. The superabsorbent materials can be natural, synthetic, and modified natural polymers and materials. In addition, the superabsorbent materials can be inorganic materials, such as silica gels, or organic compounds, such as cross-linked polymers.

[0060] These terms may be defined with additional language in the remaining portions of the specification.

[0061] Absorbent Article:

[0062] Referring to FIGS. 1 and 2, an 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 the various example embodiments of the garment 20, according to aspects of the present disclosure, the terms “longitudinal” and “lateral” have their customary meaning, as indicated by the central longitudinal axis 24 and the central lateral axis 25. The central longitudinal axis 24 lies in the plane of the garment 20 when the garment 20 is in a fully stretched and laid-flat condition, while the front and rear panels 40, 41 are separated, and is generally parallel to a vertical plane that bisects a standing wearer into left and right body halves when the garment 20 is worn. 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 end edge 32, a rear region 34 defining a rear waist end edge 36, and a crotch region 38 positioned longitudinally between the front region 30 and the rear region 34. The crotch region 38 defines two laterally opposed crotch side edges 39. The garment 20 defines a garment length 21 that extends from the front waist end edge 32 to the rear waist end edge 36.

[0063] The garment 20 includes a front panel 40 which defines a front panel leg edge 44 spaced longitudinally inward from the front waist end edge 32, and first and second laterally opposed front panel side edges 46, 48. The garment 20 also includes a rear panel 41 which defines a rear panel leg edge 45 spaced longitudinally inward from the rear waist end edge 36, and first and second laterally opposed rear panel side edges 47, 49. “Longitudinally inward (or inboard)” as used to describe garment embodiments herein means in a direction longitudinally toward the central lateral axis 25. Likewise, “laterally inward (or inboard)” as used to describe garment embodiments herein means in a direction laterally toward the central longitudinal axis 24. The front panel 40 is longitudinally spaced apart from the rear panel 41 . The front and rear panels 40 generally include elasticized materials so as to conform to a wearer’s body.

[0064] A pair of side seams 84 connects the front region 30 to the rear 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 way of adhesive, thermal, pressure, or ultrasonic bonding, or may be more readily releasable as well as refastenable, such as via the use of mechanical fastening elements.

[0065] The garment 20 may further include at least one front leg elastic member 70 disposed adjacent the front panel leg edge 44, and / or at least one rear leg elastic member 75 disposed adjacent the rear panel leg edge 45. Such leg elastic members 70 and / or 75 help to provide additional elastic support around the leg openings 28 to enhance the fit and leakage protection of the garment 20. Each leg elastic member 70, 75 may include a single ribbon, strand, or thread (or the like) of elastic material, or each may include two, three, or more ribbons, strands, or threads (or the like) of elastic material. In particular example embodiments, the rear leg elastic member 75 and / or the front leg elastic member 70 extends laterally across the entire garment width. In other example embodiments, such as that representatively illustrated in FIGS. 1 and 2, the rear leg elastic member 75 may include a pair of rear leg elastic members, such as first and second rear leg elastic members 76, 77 positioned on opposite sides of the absorbent composite 50. Similarly, the front leg elastic member 70 may include a pair of front leg elastic members, such as first and second front leg elastic members 71 , 72 positioned on opposite sides of the absorbent composite 50. In preferred example embodiments, such as that representatively illustrated in FIGS. 1 and 2, each rear leg elastic member 75 may include a plurality of elastomeric strands, and / or each front leg elastic member 70 may include a plurality of elastomeric strands.

[0066] In particular example embodiments, an absorbent composite 50 is connected to and between the front panel 40 and the rear panel 41. The absorbent composite 50 may include a composite structure formed of a liquid impermeable barrier layer 52 defining a width 53 and a length 51 , an absorbent body 54 including absorbent material, a liquid permeable liner 55, and / or crotch elastic members 56. As used herein, the term “absorbent material” may mean fibrous absorbent material, superabsorbent material (SAM), or a combination of both fibrous absorbent material and SAM. The absorbent body 54, in some example embodiments, may include a layered structure that includes multiple regions of liquid-absorbing materials such as fibrous absorbent material and / or SAM. The absorbent body 54 defines a length 61 and a width 63. Further description of example absorbent bodies 54 of the present disclosure is presented below with respect to FIG. 3.

[0067] It should be understood that the exemplary pant-like garment 20 is only one possible example of an absorbent garment or article which may be used with the described absorbent bodies 54 of the present disclosure. Such garments 20 as those shown in FIGS. 1 and 2 may be generally described as garments formed using a cross-machine direction (CD) manufacturing process. Alternative exemplary garments which may be used with the described absorbent bodies 54 may include those garments formed by a machine-direction (MD) manufacturing process. In general, the present disclosure is not meant to be limited to the specifically disclosed absorbent garments. Rather, the described absorbent bodies 54 may be used within any suitable chassis structure for retaining the described absorbent bodies 54 on a wearer. In even further contemplated example embodiments, the described absorbent bodies 54 may not be used with any chassis structure at all. Rather, the absorbent bodies 54 may be constructed so as to be able to be placed directly in contact with a wearer's body - for example using body-adhesive disposed on a body-side surface of the absorbent bodies 54.

[0068] FIGS. 3 and 4 are schematic depictions of a section of an example absorbent body 54 of the present disclosure. For example, the body 54 of FIG. 3 may be a cross-section of the absorbent body 54 in FIG. 2, as viewed along line 3-3 of FIG. 2 and with any additional layers of the garment 20 removed. In general, the absorbent body 54 of the present disclosure may include multiple different materials, with some of the materials layered together to form the body 54.

[0069] As shown in FIG. 3, the absorbent body 54 may be disposed between a bodyside liner 100, such as the liquid permeable liner 55 shown in FIG. 2, and an outer cover 110, such as the liquid impermeable barrier layer 52 shown in FIG. 2. The bodyside liner 100 may be liquid permeable and may perform well in the uptake and wicking of fluid. Conversely, the outer cover 110 may be liquid impermeable and may limit or prevent fluid transmission therethrough. The absorbent body 54 may extend between a bodyside facing portion 120 and an outwardly facing portion 122, e.g. , along a transverse direction 26, which may be mutually perpendicular to the longitudinal direction 23 and the lateral direction 22. The bodyside facing portion 120 of the absorbent body 54 may be positioned at and / or face towards the bodyside liner 100. The outwardly facing portion 122 of the absorbent body 54 may be positioned at and / or face towards the outer cover 110.

[0070] Describing the specific example embodiment of the absorbent body 54 shown in FIGS. 3 and 4, the example absorbent bodies 54 include a superabsorbent layer 130 and a mixed layer 140. The superabsorbent layer 130 and the mixed layer 140 may be discrete and separate from each other within the absorbent body 54. Thus, the absorbent body 54 may include two (2) or more layers of absorbent material with different absorbent material compositions.

[0071] The superabsorbent layer 130 may include superabsorbent particles. In example embodiments, the superabsorbent particles may be present within the superabsorbent layer 130 at no less than ninety-three percent (93%), such as no less than ninety-five percent (95%), no less than ninety-six percent (96%), by weight of the superabsorbent layer 130. The superabsorbent layer 130 may also include an adhesive for bonding the superabsorbent particles together within the superabsorbent layer 130. In example embodiments, the adhesive may be present within the superabsorbent layer 130 at no greater than seven percent (7%), such as no greater than five percent (5%), such as no greater than four percent (4%), no less than three percent (3%), by weight of the superabsorbent layer 130. The adhesive may be applied by spraying directly on the superabsorbent particles or spraying on the nonwoven layer 150.

[0072] As may be seen from the above, the superabsorbent layer 130 may be predominantly composed of superabsorbent particles. Moreover, the superabsorbent layer 130 may be essentially free of cellulosic fluff fibers and / or be fluff-free. A basis weight of the superabsorbent layer 130 may be no less than ninety grams per square meter (90 gsm) and no greater than three hundred and fifty grams per square meter (350 gsm) in example embodiments. The superabsorbent layer 130 may be constructed by patterning the superabsorbent particles for smooth distribution of the fluid.

[0073] The mixed layer 140 may include superabsorbent particles as well as cellulosic fluff fibers. In example embodiments, the superabsorbent particles may be present within the mixed layer 140 at no less than forty percent (40%) and no greater than eighty percent (80%), such as no less than forty-five percent (45%) and no greater than seventy-five percent (75%), no less than fifty percent (50%) and no greater than seventy percent (70%), such as about sixty percent (60%), by weight of the mixed layer 140. The cellulosic fluff fibers may be present within the mixed layer 140 at no less than twenty percent (20%) and no greater than sixty percent (60%), such as no less than twenty-five percent (25%) and no greater than fifty-five percent (55%), no less than thirty percent (30%) and no greater than fifty percent (50%), such as about forty percent (40%), by weight of the mixed layer 140.

[0074] As may be seen from the above, the mixed layer 140 may include both superabsorbent particles and cellulosic fluff fibers. For instance, the mixed layer 140 may be predominantly composed of superabsorbent particles and cellulosic fluff fibers. A basis weight of the mixed layer 140 may be no less than ninety grams per square meter (90 gsm) and no greater than two hundred and fifty grams per square meter (250 gsm), such as no less than one hundred grams per square meter (100 gsm) and no greater than two hundred grams per square meter (200 gsm), in example embodiments. In example embodiments, the mixed layer 140 may be essentially free of cross-linked cellulose fibers, including crimped, twisted, or curled cross-linked cellulose fibers. In example embodiments, the superabsorbent particles in the superabsorbent layer 130 may be a common type and / or grade as the superabsorbent particles in the mixed layer 140.

[0075] The example absorbent bodies 54 in FIGS. 3 and 4 may also include a nonwoven layer 150 and a nonwoven wrap 160. The nonwoven layer 150 and the nonwoven wrap 160 may be discrete and separate from each other within the absorbent body 54. Thus, the absorbent body 54 may include two (2) or more layers of nonwoven material, e.g., in addition to the superabsorbent layer 130 and the mixed layer 140

[0076] The nonwoven layer 150 may be disposed on and / or contact the superabsorbent layer 130. For instance, as shown in FIGS. 3 and 4, the nonwoven layer 150 may be wrapped or otherwise disposed around the superabsorbent layer 130. Moreover, the nonwoven layer 150 may surround the superabsorbent layer 130 with the nonwoven layer 150, e.g., in a plane that is perpendicular to the longitudinal direction 23. The nonwoven layer 150 may assist with limiting or preventing prevent escape of absorbent material, such as superabsorbent particles, from the superabsorbent layer 130.

[0077] In example embodiments, the nonwoven layer 150 may be folded around the superabsorbent layer 130 in a “D-wrap.” Thus, opposite ends of the nonwoven layer 150 may overlap in order to surround the superabsorbent layer 130 with the nonwoven layer 150. The seam of the “D-wrap” nonwoven layer 150 may be positioned at or adjacent the outwardly facing portion 122 of the absorbent body 54 as shown in FIG. 3. In other example embodiments, the seam of the “D-wrap” nonwoven layer 150 may be positioned at or adjacent the bodyside facing portion 120 of the absorbent body 54. In other example embodiments, the nonwoven layer 150 may be folded around the superabsorbent layer 130 in a “C-wrap” as shown in FIG. 11 , with a C-shaped portion 132 and a planar portion 134 collectively wrapping 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, e.g., with the superabsorbent layer 130 sandwiched between the two separate layers 136, 138 along the transverse direction 26. The two separate layers 136, 138 may be bonded to the superabsorbent layer 130 at opposite sides if the superabsorbent layer 130.

[0078] The nonwoven layer 150 may be formed of any suitable material. For instance, the nonwoven layer 150 may be liquid permeable and may perform well in the uptake and wicking of fluid. The nonwoven layer 150 may include natural and / or synthetic fibers such as, but not limited to, polyester, polypropylene, acetate, nylon, polymeric materials, cellulosic materials and combinations thereof. In various example embodiments, the nonwoven layer 150 may be hydrophilic. In various example embodiments, the nonwoven layer 150 may be hydrophobic and may be treated in any manner known in the art to be made hydrophilic.

[0079] A few 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, HYDROKNIT® materials, which are a class of materials commercially available from Kimberly-Clark World Wide, Inc., airlaid materials, through-air bonded carded webs (TABCW), and coform materials. The nonwoven layer 150 may have basis weights ranging from between about five grams per square meter (5 gsm) and about fifty-five grams per square meter (55 gsm). Other suitable materials and / or materials having basis weights different than the above identified ranges may be used in other embodiments.

[0080] The nonwoven wrap 160 may be disposed around the superabsorbent layer 130, the mixed layer 140, and the nonwoven layer 150. For instance, as shown in FIGS. 3 and 4, the nonwoven wrap 160 may be wrapped or otherwise disposed around the superabsorbent layer 130, the mixed layer 140, and the nonwoven layer 150. Moreover, the nonwoven wrap 160 may surround the superabsorbent layer 130, the mixed layer 140, and the nonwoven layer 150 with the nonwoven layer 150, e.g., in a plane that is perpendicular to the longitudinal direction 23. The nonwoven wrap 160 may assist with limiting or preventing escape of absorbent material from the absorbent body 54.

[0081] In example embodiments, the nonwoven wrap 160 may be folded around the superabsorbent layer 130, the mixed layer 140, and the nonwoven layer 150 in a “D-wrap.” Thus, opposite ends of the nonwoven wrap 160 may overlap in order to surround the superabsorbent layer 130, the mixed layer 140, and the nonwoven layer 150 with the nonwoven wrap 160. The seam of the “D-wrap” nonwoven wrap 160 may be positioned at or adjacent the outwardly facing portion 122 of the absorbent body absorbent body 54 as shown in FIG. 3. In other example embodiments, the seam of the “D-wrap” nonwoven wrap 160 may be positioned at or adjacent the bodyside facing portion 120 of the absorbent body absorbent body 54. Thus, e.g., the seam of the nonwoven wrap 160 may be positioned at or adjacent the same portion of the absorbent body absorbent body 54 in example embodiments. Other formations of the nonwoven wrap 160 are also within the scope of the present disclosure, such as “C- wraps.”

[0082] The nonwoven wrap 160 may include a tissue material, spunbond and / or meltblown material (e.g. spunbond-meltblown material or spunbond-meltblown-spunbond material), spunlace material, HYDROKNIT® material, airlaid material, through-air bonded carded web (TABCW), and coform material. Preferred materials for the nonwoven wrap 160 may have a basis weight of between about eight grams per square meter (8 gsm) and about thirty-five grams per square meter (35 gsm). Although, it should be understood these are only exemplary materials and basis weights. In general, any suitable material at any suitable basis weight may be used.

[0083] The absorbent bodies 54 of the present disclosure may include absorbent material, namely two more separate layers of absorbent material, to provide the absorbent bodies 54 with beneficial fluid intake and storage (e.g. fluid retention) qualities. For example, the absorbent bodies 54 may include: (1) the superabsorbent layer 130 predominantly composed of superabsorbent particles; and (2) the mixed layer 140 with both superabsorbent particles and cellulosic fluff fibers.

[0084] The superabsorbent layer 130 may be heavier than the mixed layer 140 in example embodiments. For instance, the superabsorbent layer 130 may be present within the garment 20 at no less than twenty-five percent (25%) and no greater than forty percent (40%), such as no less than twenty-eight percent (28%) and no greater than thirty-five percent (35%), by weight of the garment 20. The mixed layer 140 may be present within the garment 20 at no less than fifteen percent (15%) and no greater than thirty percent (30%), such as no less than nineteen percent (19%) and no greater than twenty-five percent (25%), by weight of the garment 20. Thus, e.g., the superabsorbent layer 130 may have greater absorption capacity than the mixed layer 140 due to the greater amount of absorption material within the superabsorbent layer 130 relative to the mixed layer 140 and / or due to the composition of the absorption material within the superabsorbent layer 130 relative to the mixed layer 140.

[0085] In example embodiments, the absorbent body 54 may define a thickness TA along the transverse direction 26. The thickness TA of the absorbent body 54 may be less than conventional absorbent bodies. For instance, the thickness TA of the absorbent body 54 may be no greater than four millimeters (4 cm), such as no greater than three millimeters (3 mm), such as no greater than two and a half millimeters (2.5 mm), such as no greater than two millimeters (2 mm), such as no greater than one and a half millimeters (1 .5 mm), such as no greater than one and a quarter millimeters (1 .25 mm). The superabsorbent layer 130 and the mixed layer 140 may allow such thicknesses of the absorbent body 54 while also providing rapid initial intake and limited rewet.

[0086] As noted above, the superabsorbent layer 130 may be disposed below the mixed layer 140 within the absorbent body 54. Thus, the superabsorbent layer 130 may be disposed between the mixed layer 140 and the outer cover 110. The superabsorbent particles in the superabsorbent layer 130 may provide greater absorption capacity for the liquid bodily exudates than the superabsorbent particles and cellulosic fluff fibers within the mixed layer 140. However, the superabsorbent particles and cellulosic fluff fibers within the mixed layer 140 may advantageously provide improved initial intake, e.g., relative to absorbent cores with only superabsorbent particles, while also providing desirable rewet characteristics. The absorbent body 54 may thereby advantageously capture and retain liquid bodily exudates, thereby preventing the exudates from leaking out of the garment 20 and further retaining the liquid away from a wearer's skin, which helps to promote skin health. The absorbent body 54 may also be thinner than conventional absorbent articles, e.g., along the transverse direction 26.

[0087] As shown in FIGS. 3 and 4, the absorbent body 54 may further include an acquisition and / or distribution layer 168 (referred to herein as simply acquisition layer 168) disposed between the absorbent body 54 and the bodyside liner 100 The acquisition layer 168 may be coupled to the absorbent body 54 at the bodyside facing portion 120 of the absorbent body 54. In some example embodiments, the acquisition layer 168 may be coupled to the absorbent body 54 by an adhesive. For example, an adhesive layer may be applied to the acquisition layer 168, which in turn may be applied to the absorbent body 54 at the bodyside facing portion 120. The acquisition layer 168 may preferably include materials similar to those described above with respect to the nonwoven layer 150. For example, acquisition layer 168 may preferably include tissue materials, spunbond and / or meltblown materials (e.g. spunbond-meltblown materials and spunbond-meltblown-spunbond materials), spunlace materials, HYDROKNIT® materials, airlaid materials, through-air bonded carded webs (TABCW), and coform materials and may have basis weights ranging from between about five grams per square meter (5 gsm) and about fifty-five grams per square meter (55 gsm). According to some example embodiments, the acquisition layer 168 may be a tissue, SMS, or spunbond material having a basis weight of between about seven grams per square meter (7 gsm) and about twenty grams per square meter (20 gsm) or a coform, spunlace, or airlaid material having a basis weight of between about thirty-five grams per square meter (35 gsm) and about fifty-five grams per square meter (55 gsm).

[0088] The acquisition layer 168 may facilitate fluid flow from the bodyside liner 100 and the absorbent body 54. For instance, the acquisition layer 168 and the absorbent body 54 may assist with acquisition and distribution of liquids by the garment 20 into the absorbent body 54, thereby speeding up fluid intake times.

[0089] In example embodiments, the 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 the superabsorbent particles within the garment 20 and away from the outer cover 52 as well as to provide additional void volume and / or absorbency to the garment 20 for superior fluid handling properties. Accordingly, desirable materials for use as the bottom integrity sheet 170 include bulky materials and / or absorptive material including TABCW materials, spunlace materials, tissue materials, spunbond materials, spunbond meltblown spunbond materials, and coform materials. Such materials may have a basis weight of between about ten grams per square meter (10 gsm) and about fifty grams per square meter (50 gsm), such as between about twenty grams per square meter (20 gsm) and about forty grams per square meter (40 gsm).

[0090] Additionally, in order to maintain any of the absorbent bodies 54 as a cohesive structure and to assist in stabilizing the absorbent material within the bodies 54, the bodies 54 may include additional adhesives. In general, adhesive may be applied to different materials of the bodies 54 so as to form different adhesive layers. For example, some embodiments may include an adhesive layer between the nonwoven layer 150 and the superabsorbent layer 130, e.g., applied to one or both of the nonwoven layer 150 and the superabsorbent layer 130. Additionally, or alternatively, example embodiments may include an adhesive layer between the nonwoven wrap 160 and the nonwoven layer 150 and / or the mixed layer 140, e.g., applied to one or more of the nonwoven wrap 160, the nonwoven layer 150, and the mixed layer 140.

[0091] FIGS. 5 through 10 show various example embodiments of the mixed layer 140 above the superabsorbent layer 130. It will be understood that, while not shown in FIGS. 5 through 10, the nonwoven layer 150 may be disposed between the mixed layer 140 and the superabsorbent layer 130 and / or the nonwoven layer 150 may be wrapped around the superabsorbent layer 130. As discussed in greater detail below, the mixed layer 140 and the superabsorbent layer 130 may be proportioned to facilitate initial absorption and distribution of liquid bodily exudates within the absorbent body 54.

[0092] As shown in FIGS. 5 through 10, 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 mixed layer 140 may also define a length LM along the longitudinal direction 23, and the mixed layer 140 may define a width WM along the lateral direction 22. In example embodiments, such as those shown in FIGS. 5 through 9, the length LS of the superabsorbent layer 130 may be greater than the length LM of the mixed layer 140. For instance, the length LS of the superabsorbent layer 130 may be no greater than double (2X) the length LM of the mixed layer 140. As shown in FIG. 10, the length LS of the superabsorbent layer 130 may be equal to or about equal to the length LM of the mixed layer 140 in example embodiments. In example embodiments, such as those shown in FIGS. 5 and 6, the width WS of the superabsorbent layer 130 may be greater than the width WM of the mixed layer 140. For instance, the width WS of the superabsorbent layer 130 may be no greater than double (2X) the width WM of the mixed layer 140. As shown in FIG. 7 through 10, the width WS of the superabsorbent layer 130 may be equal to or about equal to the width WM of the mixed layer 140 in example embodiments. Such sizing of the superabsorbent layer 130 relative to the mixed layer 140 may advantageously size the mixed layer 140 for initial absorption and distribution of liquid bodily exudates. Moreover, such sizing of the superabsorbent layer 130 relative to the mixed layer 140 may advantageously size superabsorbent layer 130 as a reservoir for retention of the liquid bodily exudates while also allowing sizing the mixed layer 140 for initial intake. The size and / or shape of the mixed layer 140 may be formed by utilizing a forming screen.

[0093] The mixed layer 140 may also be positioned on the superabsorbent layer 130 to facilitate initial absorption and distribution of liquid bodily exudates within the absorbent body 54. For instance, in FIGS. 5 and 7, the mixed layer 140 may be disposed closer to a front edge of the superabsorbent layer 130, which may be disposed adjacent the front waist end edge 32 of the garment 20, such that the mixed layer 140 is configured for male users. As another example, in FIGS. 6 and 8, the mixed layer 140 may be disposed closer to a rear edge of the superabsorbent layer 130, which may be disposed adjacent the rear waist end edge 36 of the garment 20, such that the mixed layer 140 is configured for female users. In the example embodiments shown in FIGS. 9 and 10, the mixed layer 140 may be disposed concentrically with the superabsorbent layer 130, e.g., such that the mixed layer 140 is configured for unisex wear, i.e. , for both male and female users.

[0094] With reference to FIGS. 7 through 10, the mixed layer 140 may also define a plurality of channels 142. The channels 142 may extend through the mixed layer 140 from a bodyside facing side 145 (FIG. 4) of the mixed layer 140 to an outward facing side 146 of the mixed layer 140, e.g., along the transverse direction 26. The channels 142 may be essentially free of the superabsorbent particles and the cellulosic fluff fibers of the mixed layer 140. Thus, e.g., one open end portion of each of the channels 142 may be disposed at the nonwoven layer 150, and an opposite open end portion of each of the channels 142 may be disposed at the nonwoven wrap 160. The channels 142 may be hollow and configured for directing liquid bodily exudates through the mixed layer 140 to the underlying superabsorbent layer 130. The channels 142 may thereby increase performance of the absorbent body 54 in terms of faster first fluid intake time and better rewet performance. For instance, the channels 142 may provide a direct flow path for the liquid bodily exudates through the mixed layer 140 to the underlying superabsorbent layer 130 in order to facilitate rapid transfer of at least a portion of the liquid bodily exudates to the superabsorbent layer 130.

[0095] The channels 142 may be positioned to facilitate initial absorption and distribution of liquid bodily exudates within the absorbent body 54. For example, as shown in FIGS. 7 through 10, the channels 142 may be disposed over a middle portion of the superabsorbent layer 130. Thus, the channels 142 may facilitate transfer of the liquid bodily exudates through the mixed layer 140 towards the center portion of the superabsorbent layer 130. The channels 142 may be oriented to facilitate initial absorption and distribution of liquid bodily exudates within the absorbent body 54. For example, as shown in FIGS. 7 through 10, the channels 142 may be elongated, e.g., along the longitudinal direction 23, in a plane that is perpendicular to the transverse direction 26. As another example, a collective open area of the channels 142 may be no less than three square centimeters (3 cm2) and no greater than twenty square centimeters (20 cm2) in a plane that is perpendicular to the transverse direction 26. Such sizing and / or shaping of the channels 142 may assist with acquisition and distribution of liquids by the garment 20 into the absorbent body 54, thereby speeding up fluid intake times.

[0096] The mixed layer 140 may include a suitable number of channels 142. As shown in FIGS. 7 through 10, the mixed layer 140 may include two channels 142 in example embodiments. For instance, the mixed layer 140 may include three, four, five, or more channels 142. In some example embodiments, as shown in FIG. 9, the mixed layer 140 may include two elongated channels 142 at the central portion of the mixed layer 140 and two or more additional channels 144, e.g., at opposite end portions of the mixed layer 140 along the longitudinal direction 23.

[0097] Formation Methods:

[0098] FIG. 13 is a schematic depiction of a method 200 of manufacturing absorbent cores, such as the absorbent bodies 54 of the present disclosure. In a first step, a core material 201 having a top side and a bottom side may be unwound from a spool including material forming the core material 201 . The core material 201 may correspond to the nonwoven layer 150 and the superabsorbent layer 130, e.g., with the nonwoven layer 150 wrapped around the superabsorbent layer 130, described previously with respect to the absorbent bodies 54 of the present disclosure. Thus, e.g., the core material 201 may include a superabsorbent layer with a nonwoven layer wrapped around the superabsorbent layer in example embodiments. The core material 201 may be formed off-line from the method 200, wound onto a roll, and the roll of core material 201 may be unwound during the method 200. It will be understood that the core material 201 may be formed in-line as part of the method 200 in other example embodiments.

[0099] As shown, a mixed absorbent material 202 that include both superabsorbent particles and cellulosic fluff fibers may be applied to the core material 201 . The mixed absorbent material 202 may correspond to the mixed layer 140 described above. Thus, e.g., the mixed absorbent material 202 may form a separate layer of absorbent material over the core material 201 . In example embodiments, superabsorbent particles and cellulosic fluff fibers may be stored in a hopper 215 and may be dispensed 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 cellulosic fluff fibers are dispensed in a metered fashion such that a designated amount of superabsorbent particles and cellulosic fluff fibers is deposited onto the first side of the core material 201 .

[0100] Next, a covering material 203 may be unwound from spool(s) and brought to cover the partial core assembly 211 , which includes the core material 201 and the mixed absorbent material 202, and form a full core assembly 221. In some example embodiments, the covering material 203 may be guided by guide rolls. The covering material 203 may correspond to the nonwoven wrap 160 in some example embodiments.

[0101] Next, the process 200 may include embossing the full core assembly 221 with embossing rolls 205. The full core assembly 221 may also be heat pressure sealed at rolls 206.

[0102] At this point, the process 200 may further include cutting the full core assembly 221 into individual absorbent bodies 54 for use in absorbent articles, such as the garment 20, with a cutter 207. However, the process 200 may include further steps, for example in order to form absorbent cores such as those represented. For example, process 200 may further include transporting the formed full core assembly 221 , which is a laminate of the superabsorbent layer 130, the mixed layer 140, the nonwoven layer 150, and the nonwoven wrap 160 to a folder 208 for folding the garments 20.

[0103] FIG. 18 is an exemplary schematic depiction of another absorbent structure formation process 300. Process 300 may include unwinding a first web material 310 and moving the first web material 310 in a machine direction 302. An adhesive 330 may be applied to a surface of the first web material 310. An adhesive applicator may apply the adhesive 330 to the first web material 310 pneumatically or through various coating methods - or any other suitable application method - in the form of dots, beads, swirls, or any other suitable pattern. Although, it should be noted that the adhesive 330 may be optional and not present in other example embodiments. Accordingly, in such example embodiments, the adhesive 330 is not placed onto the first web material 310.

[0104] The first web material 310 may continue in the machine direction 302, arriving at a first absorbent material deposition station 320. The first absorbent material deposition station 320 may include a drum 322 with a movable, foraminous forming surface. A vacuum duct 324 may be located radially inwardly of the forming surface on the drum 322. The vacuum duct 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 drum 322 is movable. The forming chamber 326 has an entrance where the forming surface on the drum 322 enters the chamber 326 substantially free of absorbent material and also has an exit where the forming surface on the drum 322 leaves the chamber 326 substantially filled with absorbent material. A fiberizer may provide fibrous material into the forming chamber 326. In addition to the fibers, other component materials may also be delivered into the forming chamber 326. For example, particles or fibers of superabsorbent material may be introduced into the forming chamber 326 by conventional mechanisms, such as pipes, channels, spreaders, nozzles and the like, as well as combinations thereof.

[0105] The vacuum source duct 324 provides a vacuum pressure relative to the interior of the chamber 326. As the forming surface on the drum 322 enters and then traverses through the forming chamber 326, the fibrous material and the superabsorbent material are operatively carried or transported onto the first web material 310 by an entraining air stream that is drawn through the forming surface on the drum 322. Thus, the forming chamber 326 can serve to direct and concentrate the air-entrained fibers and particles, and to provide a desired velocity profile in the air-entrained stream of fibers and particles.

[0106] The foraminous forming surface may be defined on the drum 322 by a series of forms, which are arranged end-to-end around the periphery of the forming drum 322. Each form may have a substantially identical pattern in which fibrous material and superabsorbent material are deposited. The patterns may correspond to a desired shape of individual absorbent cores and may repeat over the circumference of the drum 322.

[0107] The forming surface on the drum 322 that is carrying an air formed fibrous web 321, which includes the fibers and particles, may be moved to a release zone of the first absorbent material deposition station 320. In the release zone, vacuum causes the web 321 to transfer from the forming surface of the drum 322 onto the first web material 310. The release can be assisted by the application of air pressure from the interior of the drum 322. The first web material 310 receives the formed fibrous web 321 from the forming drum 322 and conveys the web 321 to a collection area or to a location for further processing (not shown). A vacuum suction box 332 may be located below the first web material 310 to remove the web 321 from the forming surface of the drum 322. The vacuum box 332 may define a plenum beneath the portion of the first web material 310 in close proximity to the forming surface so that a vacuum is communicated to the fibrous web 321 on the drum 322. Removal of the web 321 can alternatively be accomplished by the weight of the web, by centrifugal force, by mechanical ejection, by positive air pressure or by some combination or by another suitable method. The removed fibrous web includes an interconnected series of absorbent cores, and each body has a selected surface contour which substantially matches the contour provided by the corresponding portions of the forming surface upon which each individual pad was formed.

[0108] From the first absorbent material deposition station 320, the first web material 310 and the web 321 thereon may continue in the machine direction 302, arriving at a second absorbent material deposition station 340. At the second absorbent material deposition station 340, superabsorbent material intermixes with one or more adhesives prior to depositing onto a second web material 312, for example in a mixing region, and ultimately deposits onto the second web material 312.

[0109] The superabsorbent material flows from a hopper 342 and through chute toward the second web material 312. The hopper 342 may be a bulk solid pump or feeder configured to maintain a consistent flow of the superabsorbent material through the second absorbent material deposition station 340. The flow rate of the superabsorbent material out of the hopper 342 may be adjustable such that the hopper 342 can deliver different amounts of superabsorbent material, resulting in different basis weights of superabsorbent material in the finished absorbent structures 301 . Such differences in basis weights of superabsorbent material may allow the formed absorbent structures 301 to be used in different absorbent end uses - such as in diapers, feminine articles, adult care garments, bandages and the like.

[0110] The chute may be oriented such that the superabsorbent material exits the chute falling substantially in a vertical direction. The superabsorbent material may preferably be fed through the second absorbent material deposition station 340 by gravity, without any pneumatic force. However, other application methods for the superabsorbent material from the chute may also be used. In general, a "sheet” or “stream” of superabsorbent material may flow from the chute towards the second web material 312.

[0111] As the superabsorbent material falls toward the second web material 312, adhesive applicators 344 may spray adhesive toward the falling superabsorbent material. The adhesive intermixes with the falling superabsorbent material prior to the mixture of the superabsorbent material and the adhesive depositing onto the second web material 312. Two or more adhesive applicators 344 may be used for each stream of superabsorbent material.

[0112] As the second web material 312 passes the second absorbent material deposition station 340, a deposited mixture 346 of adhesives and superabsorbent material forms. The adhesive may operate to immobilize the superabsorbent material onto the second web material 312.

[0113] During the deposition of the mixture 346, vacuum energy may optionally be applied to the second web material 312. For example, the second web material 312 may be supported by a forming surface - such as a forming belt or forming drum as is 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 web material 312 is located. Accordingly, the second web material 312, along with the mixture 346 as the mixture 346 is falling toward the second web material 312, may be drawn to the forming surface due to the applied vacuum energy. Such vacuum energy may help to control the spread of the mixture 346 as it is falling toward the second web material 312, thereby helping to form a relatively more uniform absorbent structure 301 .

[0114] A third web material 314 may further be applied to the deposited mixture 346. According to some example aspects of the present disclosure, the combination of the second web material 312, the deposited mixture 346, and the third web material 314 may be applied to the first web material 310 and the web 321. For instance, the combination of the second web material 312, the deposited mixture 346, and the third web material 314 may be adhered to the first web material 310 and the web 321 to form an absorbent assembly 316.

[0115] The absorbent assembly 316 may pass through a folder 350 to fold the first web material 310 around the other portions of the absorbent assembly 316. The absorbent assembly 316 may also pass through one or more nip stations 360 to help compress the components together. In general, the nip station 360 may apply a pressure to the combination of the first web material 310, the web 321 , the second web material 312, the deposited mixture 346, and the third web material 314 to help further connect the deposited mixtures to the web materials 310, 312, 314.

[0116] After the one or more nip stations 360, the combination of the absorbent assembly 316 may pass to a cutting station where the connected length of the first web material 310, the web 321 , the second web material 312, the deposited mixture 346, and the third web material 314 may be cut into individual absorbent structures 301 . These individual absorbent structures 301 may then be combined into a manufacturing process for producing the various absorbent products.

[0117] FIGS. 13 and 18 depicts step performed in a particular order for purposes of illustration and discussion. Those of ordinary skill in the art, using the disclosures provided herein, will understand that the steps of any of the methods discussed herein may be adapted, rearranged, expanded, omitted, or modified in various ways without deviating from the scope of the present disclosure.

[0118] Test Methods:

[0119] Intake and Rewet Test Method

[0120] The following test was conducted to determine fluid intake and rewet. This test categorizes the amount of fluid remaining near the surface of the diaper shortly after insult, as well as quantifies the amount of fluid not locked up by absorbent under high pressure after a longer wait and multiple insults. For successful usage, the product must both intake fluid quickly through the layers of the absorbent core, in addition to holding on to fluid to ensure that the fluid does not flow back out when subjected to high pressure. The volume of loadings and the rate of fluid delivery are predefined based on previous consumer studies with the product. These values can vary from product to product. Equipment and Supplies for the testing include: (1) a top loading electronic balance capable of reading 0.001 gram; (2) saline solution, 0.9 + 0.005% (w / w) aqueous isotonic saline; (3) countdown timer, readable to 0.1 second; (4) rectangular plexiglass plate with dimensions of length = 300 mm and width = 100 mm and including an open cylinder located in a central area of the plate, the internal diameter of the cylinder being 38 mm and the height being 125 mm; (5) two weights of 4 kg each; (6) blotter paper verigood grade, white, 100 lb, 475 by 600 mm (19 by 24 inches) long stock, 250 sheets per ream, cut to a specified size of 88 x 300 mm + / - 13 mm (3 5 by 12 inches); (7) polycarbonate plate (3 675 mm thick) cut to 114 mm wide x 432 mm long (4 5 by 17 inches) and weighing 177 grams; (8) funnel polyethylene, 4 ounce capacity; (9) low tack two-sided tape or attachment material to secure product flat on surface; (10) stopwatch, readable to 0.1 second; and (11) ruler.

[0121] Sample Preparation for the testing is as follows. Based on the product size determine insult size and rate from table below.

[0122] Next, weigh product to the nearest 0.01 grams and record, discard specimens out of weight range determined by requestor if applicable.

[0123] For the testing setup, ensure saline is at room temperature, have three countdown timers set for 30 seconds, 2 minutes, and 15 minutes.

[0124] For the testing, first, place the product on a flat plane and fix the top and bottom ends to the two-sided tape so that the product is stretched and the absorbent core lays flat. Second, place the board with open cylinder on the stretched product so that the top edge of the plate is aligned with the edge of the absorbent core. Put the funnel in the top of the open cylinder in the plate. Third, weigh one sheet of blotter paper on the balance readable to three decimal places. Record the weight of the paper. Fourth, pour the specified quantity of saline solution into the funnel in accordance with the size of the product being tested by following the instructions in the table below. Simultaneously activate the stopwatch. Fifth, stop the stopwatch as soon as the liquid passes completely from the cylinder and into the product (no liquid being on the surface of the product). Start the timer set to 30 seconds and the timer set to 15 minutes. Sixth, record the intake time. Seventh, after waiting 30 seconds, remove the plate with the open cylinder. Place the pre-weighed blotter paper on the product and place the polycarbonate board on top of the product. Eighth, start the timer set to 2 minutes. Nineth, after waiting 2 minutes, remove the polycarbonate board and blotter paper. Place the plate with the open cylinder on the product again and leave on the product for the duration of the wait. Tenth, weigh the blotter paper to the nearest thousandth, and record the weight. Eleventh, mark the two ends down the length of the blotter paper that the fluid extends to. Measure that distance in centimeters lengthwise down the blotter paper and widthwise. Multiply those two distances together to get the area (spread) of the fluid. Record spread. Twelfth, after the 15 minute wait, place the one weight on both sides of the cylinder on the board. Pour the specified quantity of saline solution, depending on the table below, into the funnel placed in the cylinder. Simultaneously start the stopwatch, and start the countdown timer set to 15 minutes. Thirteenth, stop the stopwatch as soon as the liquid passes completely through the cylinder and into the product (no liquid being on the surface of the product). Record the second intake time. Leave the plate with the open cylinder and weights on the product for the duration of wait time. Fourteenth, weigh two sheets of blotter paper, and record the weight to three decimal places. Fifteenth, after the 15 minute wait, remove the weights and rectangular board with cylinder. Place the preweighed blotter paper onto the product, and then place the polycarbonate board and the two weights on top of that. Start the timer set for 2 minutes. Sixteenth, after the 2 minute wait, remove the weights, polycarbonate board, and blotter paper. Immediately weigh the blotter paper on a scale readable to three decimal places and record the weight. Seventeenth, mark the two ends down the length of the blotter paper that the fluid extends to. Measure that distance in centimeters lengthwise down the blotter paper and widthwise. Multiply those two distances together to get the area (spread) of the fluid. Record spread. Eighteenth, remove the product from the surface. Weigh the product and record the weight.

[0125] Examples:

[0126] Performance of a sample inventive absorbent article (Sample #2) was evaluated relative to a comparative conventional absorbent article (Sample #1).

[0127] The comparative Sample #1 had a fluff-free absorbent core. The comparative sample was a Huggies ® Naturemade Summer absorbent article.

[0128] The inventive Sample #2 was made with a hybrid absorbent core having a superabsorbent layer and a mixed layer. The superabsorbent layer was fluff-free and included superabsorbent particles at about ninety-three percent (93%) by weight of the superabsorbent layer. The mixed layer was predominantly superabsorbent particles blended with cellulosic fluff fibers with the superabsorbent particles and the cellulosic fluff fibers present at about one hundred percent (100%) by weight of the mixed layer with a ratio of the superabsorbent particles to the cellulosic fluff fibers was about 2:3 by weight.

[0129] The comparative Sample #1 and the inventive Sample #2 were both evaluated for first, second, and third initial intake values. The results are provided below in the T able 1 as well as the chart in FIG. 14.

[0130] Table 1

[0131] As may be seen above in Table 1, the intakes of the inventive Sample #2 was superior to that of the comparative Sample #1. Moreover, the inventive Sample #2 had an increase in the initial absorption intake from 18.03 seconds to 11 .22 seconds, which corresponds to a performance improvement of about 38% for the initial absorption intake. The total sum of the intakes increased from 361 .46 seconds to 66.44 seconds, which corresponds to a performance improvement of about 82%. Thus, the inventive Sample #2 was superior to the comparative Sample #1 with regards to first, second, and third intakes as well as total intake.

[0132] The comparative Sample #1 and the inventive Sample #2 were also evaluated for run-off values. The results are provided below in the Table 2 as well as the chart in FIG. 15.

[0133] Table 2

[0134] As may be seen above in Table 2, the run-off of the inventive Sample #2 was superior to that of the comparative Sample #1 . Moreover, the inventive Sample #2 had no run-off while the inventive Sample #2 had 6.66 g of run-off.

[0135] By placing the mixed layer over the superabsorbent layer in the inventive Sample #2, the longitudinal and transverse flow of liquid bodily exudates may be controlled to reduce leakage via the enhanced initial absorption intake.

[0136] The comparative Sample #1 and the inventive Sample #2 were further evaluated for second, high pressure rewet values. The results are provided below in the Table 3 as well as the chart in FIG. 16.

[0137] Table 3 ["Sample 2 | 2.31 |

[0138] As may be seen above in Table 3, the second, high pressure rewet of the inventive Sample #2 was superior to that of the comparative Sample #1 . Moreover, the inventive Sample #2 had an increase in the second, high pressure rewet from 7.44 grams to 2.31 grams, which corresponds to a performance improvement of about 69% for the second, high pressure rewet.

[0139] The comparative Sample #1 and the inventive Sample #2 were further evaluated for side compression. The results are provided below in the Table 4 as well as the chart in FIG. 17.

[0140] Table 4

[0141] As may be seen above in Table 4, the side compression of the inventive Sample #2 was superior to that of the comparative Sample #1 . Moreover, the inventive Sample #2 had an increase in the side compression from 449.3 g / f to 305.1 g / f, which corresponds to a performance improvement of about 32% for the side compression. Thus, the side compression of the inventive Sample #2 was significantly more flexible in the crotch region after absorption relative to the comparative Sample #1.

[0142] These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims.

[0143] EXAMPLE EMBODIMENTS

[0144] First example embodiment: An absorbent article, comprising: a bodyside liner; an outer cover; and an absorbent core assembly disposed between the bodyside 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 present within the superabsorbent layer at no less than ninety-five percent by weight of the superabsorbent layer, the adhesive present within the superabsorbent layer at no greater than five percent by weight of the superabsorbent layer, a nonwoven layer contacting the superabsorbent layer, a mixed layer comprising superabsorbent particles and cellulosic fluff fibers, the mixed layer disposed between the nonwoven layer and the bodyside liner, the superabsorbent particles present within the mixed layer at no less than forty percent and no greater than eighty percent by weight of the mixed layer, the cellulosic fluff fibers present within the mixed layer at no less than twenty percent and no greater than sixty percent by weight of the mixed layer, and a nonwoven wrap disposed around the superabsorbent layer and the mixed layer, wherein the mixed layer defines a plurality of channels that extend through the mixed layer from a bodyside facing side of the mixed layer to an outward facing side of the mixed layer, the plurality of channels being essentially free of the superabsorbent particles and the cellulosic fluff fibers of the mixed layer.

[0145] Second example embodiment: The absorbent article of the first example embodiment, wherein the superabsorbent particles are present within the mixed layer at about seventy percent by weight of the mixed layer, and the cellulosic fluff fibers are present within the mixed layer at about thirty percent by weight of the mixed layer.

[0146] Third example embodiment: The absorbent article of either the first example embodiment or the second example embodiment, wherein the mixed layer is present within the absorbent article at no less than ten percent and no greater than thirty percent by weight of the absorbent article.

[0147] Fourth example embodiment: The absorbent article of any one of the first through third example embodiments, wherein the superabsorbent layer is present within the absorbent article at no less than twenty percent and no greater than forty percent by weight of the absorbent article.

[0148] Fifth example embodiment: The absorbent article of any one of the first through fourth example embodiments, wherein the nonwoven layer is wrapped around the mixed layer.

[0149] Sixth example embodiment: The absorbent article of any one of the first through fifth example embodiments, wherein: the absorbent core assembly defines a longitudinal direction, a lateral direction, and a transverse direction that are mutually perpendicular; the mixed layer is disposed between the nonwoven layer and the bodyside liner along the transverse direction; the superabsorbent layer defines a length along the longitudinal direction, the mixed layer defines a length along the longitudinal direction, the superabsorbent layer defines a width along the lateral direction, the mixed layer defines a width along the lateral direction, the superabsorbent layer defines a thickness along the transverse direction, the mixed layer defines a thickness along the transverse direction; the width of the mixed layer is no less than the width of the superabsorbent layer; the length of the mixed layer is no greater than the length of the superabsorbent layer; and the length of the mixed layer is no greater than the length of the superabsorbent layer.

[0150] Seventh example embodiment: The absorbent article of any one of the first through sixth example embodiments, wherein an end portion of each of the plurality of channels is disposed at an open towards the nonwoven layer.

[0151] Eighth example embodiment: An absorbent article, comprising: a bodyside liner; an outer cover; and an absorbent core assembly disposed between the bodyside liner and the outer cover, the absorbent core assembly comprising a superabsorbent layer comprising superabsorbent particles, the superabsorbent particles present within the superabsorbent layer at no less than ninety-three percent by weight of the superabsorbent layer, a nonwoven layer, a mixed layer comprising superabsorbent particles and cellulosic fluff fibers, the mixed layer disposed between the nonwoven layer and the bodyside liner, and a nonwoven wrap disposed around the superabsorbent layer and the mixed layer.

[0152] Nineth example embodiment: The absorbent article of the eighth example embodiment, wherein the superabsorbent particles are present within the superabsorbent layer at no less than ninety-six percent by weight of the superabsorbent layer.

[0153] Tenth example embodiment: The absorbent article of either the eighth example embodiment or the nineth example embodiment, wherein the superabsorbent particles are present within the mixed layer at no less than forty percent and no greater than eighty percent by weight of the mixed layer, and the cellulosic fluff fibers are present within the mixed layer at no less than twenty percent and no greater than sixty percent by weight of the mixed layer.

[0154] Eleventh example embodiment: The absorbent article of any one of the eighth through tenth example embodiments, wherein the superabsorbent particles are present within the mixed layer at about seventy percent by weight of the mixed layer, and the cellulosic fluff fibers are present within the mixed layer at about thirty percent by weight of the mixed layer.

[0155] Twelfth example embodiment: The absorbent article of any one of the eighth through eleventh example embodiments, wherein the mixed layer is present within the absorbent article at no less than ten percent and no greater than thirty percent by weight of the absorbent article. Thirteenth example embodiment: The absorbent article of any one of the eighth through twelfth example embodiments, wherein the mixed layer is present within the absorbent article at no less than nineteen percent by weight of the absorbent article.

[0156] Fourteenth example embodiment: The absorbent article of any one of the eighth through thirteenth example embodiments, wherein the superabsorbent layer is present within the absorbent article at no less than twenty percent and no greater than forty percent by weight of the absorbent article.

[0157] Fifteenth example embodiment: The absorbent article of any one of the eighth through fourteenth example embodiments, wherein the superabsorbent layer is present within the absorbent article at no less than twenty-eight percent by weight of the absorbent article.

[0158] Sixteenth example embodiment: The absorbent article of any one of the eighth through fifteenth example embodiments, wherein the superabsorbent layer is present within the absorbent article at no less than twenty percent and no greater than forty percent by weight of the absorbent article. Seventeenth example embodiment: The absorbent article of any one of the eighth through sixteenth example embodiments, wherein the superabsorbent layer is present within the absorbent article at about no less than twenty-eight percent by weight of the absorbent article.

[0159] Eighteenth example embodiment: The absorbent article of any one of the eighth through seventeenth example embodiments, wherein the superabsorbent layer comprises an adhesive that bonds the superabsorbent particles together in the superabsorbent layer.

[0160] Nineteenth example embodiment: The absorbent article of any one of the eighth through eighteenth example embodiments, wherein the adhesive is present within the superabsorbent layer at no greater than five percent by weight of the superabsorbent layer.

[0161] Twentieth example embodiment: The absorbent article of any one of the eighth through nineteenth example embodiments, wherein the nonwoven layer is wrapped around the mixed layer.

[0162] Twenty-First example embodiment: The absorbent article of any one of the eighth through twentieth example embodiments, wherein: the absorbent core assembly defines a longitudinal direction, a lateral direction, and a transverse direction that are mutually perpendicular; the mixed layer is disposed between the nonwoven layer and the bodyside liner along the transverse direction; the superabsorbent layer defines a length along the longitudinal direction, the mixed layer defines a length along the longitudinal direction, the superabsorbent layer defines a width along the lateral direction, and the mixed layer defines a width along the lateral direction; the width of the mixed layer is no less than the width of the superabsorbent layer; and the length of the mixed layer is less than the length of the superabsorbent layer.

[0163] Twenty-Second example embodiment: The absorbent article of any one of the eighth through twenty-first example embodiments, wherein the mixed layer defines a plurality of channels that extend through the mixed layer from a bodyside facing side of the mixed layer to an outward facing side of the mixed layer, the plurality of channels being essentially free of the superabsorbent particles and the cellulosic fluff fibers of the mixed layer.

[0164] Twenty-Third example embodiment: The absorbent article of any one of the eighth through twenty-second example embodiments, wherein an end portion of each of the plurality of channels is disposed at an open towards the nonwoven layer.

Claims

What Is Claimed:1 . An absorbent article, comprising: a bodyside liner; an outer cover; and an absorbent core assembly disposed between the bodyside 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 present within the superabsorbent layer at no less than ninety-five percent by weight of the superabsorbent layer, the adhesive present within the superabsorbent layer at no greater than five percent by weight of the superabsorbent layer, a nonwoven layer contacting the superabsorbent layer, a mixed layer comprising superabsorbent particles and cellulosic fluff fibers, the mixed layer disposed between the nonwoven layer and the bodyside liner, the superabsorbent particles present within the mixed layer at no less than forty percent and no greater than eighty percent by weight of the mixed layer, the cellulosic fluff fibers present within the mixed layer at no less than twenty percent and no greater than sixty percent by weight of the mixed layer, and a nonwoven wrap disposed around the superabsorbent layer and the mixed layer, wherein the mixed layer defines a plurality of channels that extend through the mixed layer from a bodyside facing side of the mixed layer to an outward facing side of the mixed layer, the plurality of channels being essentially free of the superabsorbent particles and the cellulosic fluff fibers of the mixed layer.

2. The absorbent article of claim 1 , wherein the superabsorbent particles are present within the mixed layer at about seventy percent by weight of the mixed layer, and the cellulosic fluff fibers are present within the mixed layer at about thirty percent by weight of the mixed layer.

3. The absorbent article of claim 1 , wherein the mixed layer is present within the absorbent article at no less than ten percent and no greater than thirty percent by weight of the absorbent article.

4. The absorbent article of claim 3, wherein the superabsorbent layer is present within the absorbent article at no less than twenty percent and no greater than forty percent by weight of the absorbent article.

5. The absorbent article of claim 1 , wherein the nonwoven layer is wrapped around the mixed layer.

6. The absorbent article of claim 1 , wherein: the absorbent core assembly defines a longitudinal direction, a lateral direction, and a transverse direction that are mutually perpendicular; the mixed layer is disposed between the nonwoven layer and the bodyside liner along the transverse direction; the superabsorbent layer defines a length along the longitudinal direction, the mixed layer defines a length along the longitudinal direction, the superabsorbent layer defines a width along the lateral direction, the mixed layer defines a width along the lateral direction, the superabsorbent layer defines a thickness along the transverse direction, the mixed layer defines a thickness along the transverse direction; the width of the mixed layer is no less than the width of the superabsorbent layer; the length of the mixed layer is no greater than the length of the superabsorbent layer; and the length of the mixed layer is no greater than the length of the superabsorbent layer.

7. The absorbent article of claim 1 , wherein an end portion of each of the plurality of channels is disposed at an open towards the nonwoven layer.

8. An absorbent article, comprising: a bodyside liner; an outer cover; and an absorbent core assembly disposed between the bodyside liner and the outer cover, the absorbent core assembly comprising a superabsorbent layer comprising superabsorbent particles, the superabsorbent particles present within the superabsorbent layer at no less than ninety-three percent by weight of the superabsorbent layer, a nonwoven layer,a mixed layer comprising superabsorbent particles and cellulosic fluff fibers, the mixed layer disposed between the nonwoven layer and the bodyside liner, and a nonwoven wrap disposed around the superabsorbent layer and the mixed layer.

9. The absorbent article of claim 8, wherein the superabsorbent particles are present within the superabsorbent layer at no less than ninety-six percent by weight of the superabsorbent layer.

10. The absorbent article of claim 8, wherein the superabsorbent particles are present within the mixed layer at no less than forty percent and no greater than eighty percent by weight of the mixed layer, and the cellulosic fluff fibers are present within the mixed layer at no less than twenty percent and no greater than sixty percent by weight of the mixed layer.11 . The absorbent article of claim 10, wherein the superabsorbent particles are present within the mixed layer at about seventy percent by weight of the mixed layer, and the cellulosic fluff fibers are present within the mixed layer at about thirty percent by weight of the mixed layer.

12. The absorbent article of claim 8, wherein the mixed layer is present within the absorbent article at no less than ten percent and no greater than thirty percent by weight of the absorbent article.

13. The absorbent article of claim 12, wherein the mixed layer is present within the absorbent article at no less than nineteen percent by weight of the absorbent article.

14. The absorbent article of claim 12, wherein the superabsorbent layer is present within the absorbent article at no less than twenty percent and no greater than forty percent by weight of the absorbent article.

15. The absorbent article of claim 14, wherein the superabsorbent layer is present within the absorbent article at no less than twenty-eight percent by weight of the absorbent article.

16. The absorbent article of claim 8, wherein the superabsorbent layer is present within the absorbent article at no less than twenty percent and no greater than forty percent by weight of the absorbent article.

17. The absorbent article of claim 16, wherein the superabsorbent layer is present within the absorbent article at about no less than twenty-eight percent by weight of the absorbent article.

18. The absorbent article of claim 8, wherein the superabsorbent layer comprises an adhesive that bonds the superabsorbent particles together in the superabsorbent layer.

19. The absorbent article of claim 18, wherein the adhesive is present within the superabsorbent layer at no greater than five percent by weight of the superabsorbent layer.

20. The absorbent article of claim 8, wherein the nonwoven layer is wrapped around the mixed layer.21 . The absorbent article of claim 8, wherein: the absorbent core assembly defines a longitudinal direction, a lateral direction, and a transverse direction that are mutually perpendicular; the mixed layer is disposed between the nonwoven layer and the bodyside liner along the transverse direction; the superabsorbent layer defines a length along the longitudinal direction, the mixed layer defines a length along the longitudinal direction, the superabsorbent layer defines a width along the lateral direction, and the mixed layer defines a width along the lateral direction; the width of the mixed layer is no less than the width of the superabsorbent layer; and the length of the mixed layer is less than the length of the superabsorbent layer.

22. The absorbent article of claim 8, wherein the mixed layer defines a plurality of channels that extend through the mixed layer from a bodyside facing side of the mixed layer to an outward facing side of the mixed layer, the plurality of channels being essentially free of the superabsorbent particles and the cellulosic fluff fibers of the mixed layer.

23. The absorbent article of claim 22, wherein an end portion of each of the plurality of channels is disposed at an open towards the nonwoven layer.

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