Liquid absorbent pet mat

Abstract

A liquid absorbent pet mat is disclosed. The pet mat includes an absorbent core positioned between a liquid permeable top layer and a liquid impermeable backing layer. A pattern is embossed at least into the absorbent core for producing containment areas well suited for holding and retaining liquids. An adhesive can be applied around the entire perimeter of the product for preventing liquid migration through the edges.

Description

[0001] LIQUID ABSORBENT PET MAT

[0002] CROSS-REFERENCE TO RELATED APPLICATION

[0003] The present application is related and has right of priority to U.S. Provisional Patent Application No. 63 / 633,244 filed on April 12, 2024, which is incorporated by reference in its entireties for all purposes.

[0004] BACKGROUND

[0005] Pet mats, such as dog mats or pads, are designed for absorbing liquids and other body exudates and are typically made from materials that have high absorbency properties, such as microfibers, cotton, or specialized absorbent polymers. The primary purpose of these mats is to protect floors and furniture from damage caused by spills or incontinence and to make cleaning up easier.

[0006] Liquid absorbable pet mats are useful in various situations. For instance, the pet mats can be very practical for containing any spills or accidents that may occur when traveling with pets. Pet mats are also commonly used in veterinary clinics and grooming salons to provide a clean and sanitary surface for pets during procedures or grooming sessions. The pet mats can help contain any bodily fluids or grooming products that may be spilled during the process. Pet mats can also be very useful during temporary living situations or while staying in a pet-friendly accommodation. Pet mats are also used during extended home absences, when pets are unaccompanied for longer than normal periods. The pet mats, for instance, can provide a quick and easy solution for protecting floors and furniture from pet accidents. Similarly, the mats are well suited for use during emergencies such as natural disasters or evacuations. Pet mats, for instance, can be incorporated into emergency kits for pets, providing a clean surface for them to rest and for preventing liquid spills from damaging surfaces.

[0007] Pet mats are often used to manage leaks and accidents for pets that are experiencing incontinence issues. For instance, older dogs and dogs recovering from surgery typically experience incontinence issues.

[0008] Pet mats are also useful during the process of housebreaking or training young pets to use a designated potty area. The pet mats can be placed indoors to protect floors or other surfaces while the pet learns proper bathroom habits. The pet mats are particularly useful, for instance, overnight when the young pets are not being accompanied by their owner.

[0009] Pet mats are typically made using materials that have high absorbency properties. Many pet mats are disposable and designed for one-time use. In one application, for instance, a disposable pet mat can contain absorbent polymers, such as superabsorbent polymers, which can absorb and retain large amounts of liquid. These polymers are typically combined with other materials like non-woven fabrics or papers to create a structure for the mat. Pet mats are typically assembled and then cut and shaped into a desired size. For instance, large rolls of materials may be cut into individual mat-size pieces. Once pet mats are cut and shaped, they are packaged into individual units for sale.

[0010] Although various pet mats are commercially available, various improvements are still needed and desired in the art. For instance, many pet mats do not have sufficient absorbent capacity for holding and retaining liquid spills or urine insults. Mats that have sufficient absorbent capacity, however, also tend to leak through the sides of the mat over time. In addition, many mats degrade in performance when the mats are folded and / or shipped. For instance, absorbent materials in the mat have a tendency to clump and migrate within the mat creating areas of reduced absorbency within the product.

[0011] SUMMARY

[0012] In general, the present disclosure is directed to a liquid absorbent pet mat. The pet mat can be disposable and designed for one-time use. The liquid absorbent pet mat of the present disclosure is multi-layered and constructed such that the pet mat has excellent absorbent capacity in conjunction with very fast liquid intake rates. The pet mat can also be configured so as to prevent any liquid leaks through the edges of the mat once the mat has been insulted with a liquid.

[0013] For instance, in one embodiment, the present disclosure is directed to a liquid absorbent pet mat comprising a multi-layer planar structure. The pet mat has a top liquid permeable layer attached to a liquid impermeable backing layer along a perimeter of the pet mat. An absorbent core is contained between the top layer and the backing layer. The absorbent core comprises a superabsorbent material. In one aspect, the liquid absorbent pet mat further includes a pattern of embossments formed into at least the absorbent core. For instance, the pattern of embossments can be formed into the top layer in combination with the absorbent core. The pattern of embossments includes containment areas for a superabsorbent material so that the superabsorbent material does not migrate or shift during packaging, shipping, or handling of the product. The containment areas are surrounded by open areas. The open areas dramatically increase liquid intake rates, especially in relation to prior embossed products.

[0014] In one aspect, for instance, the pattern of embossments can be formed by line elements. In one embodiment, the line elements can extend over a length or width of the absorbent core. The line elements can be continuous or discontinuous. In one aspect, the pattern of embossments can include pairs of line elements spaced apart. Each pair of line elements can intersect in order to form the containment areas.

[0015] In an alternative embodiment, the line elements can form discrete shapes. The shapes can be geometrical or fanciful. In one embodiment, for instance, the discrete shapes may be in the shape of dog paws. In one aspect, the discrete shapes can have different sizes for creating containment areas that have different sizes.

[0016] In still another embodiment, the pattern of embossments can include line elements that extend over a length or width of the absorbent core in combination with line elements that form discrete shapes. The discrete shapes, for instance, can be positioned between the line elements that extend over the width or length. In one aspect, the pattern of embossments can improve functionality by maintaining the superabsorbent material within the containment areas for rapidly receiving liquids and holding the liquids within the contained areas. The containment areas, for instance, can absorb and entrap liquid. The containment areas also can be positioned to direct liquids away from the edges of the pet mat to minimize pad side leakage.

[0017] The pattern of embossments can produce a surface area of the pet mat that includes containment areas surrounded by open areas. The open areas can account for from about 10% to about 90% of the surface area of the absorbent core, such as from about 40% to about 85% of the surface area of the absorbent core. The containment areas, on the other hand, can occupy from about 10% to about 60% of the surface area of the absorbent core, such as from about 15% to about 50% of the surface area of the absorbent core.

[0018] In one aspect, the absorbent core contains a superabsorbent material combined with fluff cellulose fibers. The absorbent core can include at least two layers For instance, the absorbent core can include a first layer comprising a tissue web and a second layer comprising superabsorbent material. The superabsorbent material can be positioned on the tissue web. In one aspect, the absorbent core can further include a third layer that can comprise a surge material. The third layer can be positioned over the second layer and the first layer. The layer containing the superabsorbent material can generally have a basis weight of from about 30 gsm to about 100 gsm, such as from about 40 gsm to about 80 gsm. In one aspect, the absorbent layer can contain a superabsorbent material in an amount from about 15 gsm to about 35 gsm and can contain cellulose fluff in an amount from about 25 gsm to about 45 gsm. The top liquid permeable liner positioned over the absorbent core, in one embodiment, can comprise a spunbond web or a carded web

[0019] The pet mat of the present disclosure can display excellent fluid handling properties. For instance, the pet mat can display a liquid intake rate of less than about 24 seconds, such as less than about 22 seconds. The pet mat can display a saturation capacity of greater than about 0.3 g / cm2, such as greater than about 0.32 g / cm2, such as greater than about 0.34 g / cm2.

[0020] In another embodiment, the liquid absorbent pet mat of the present disclosure can include a perimeter area well suited for preventing any liquids absorbed by the pet mat from leaking through the sides of the mat. For example, in one aspect, the top liquid permeable layer and the backing layer can be attached together by an adhesive. The adhesive can be located only along a perimeter of the top layer and the backing layer. For example, in one aspect, the adhesive can extend around the entire perimeter of the top layer and the backing layer. The application of the adhesive around the perimeter can be continuous or discontinuous. The adhesive can directly attach the top layer to the backing layer. For example, the absorbent core can be positioned between the top layer and the backing layer in a manner such that the absorbent core does not extend into the perimeter margin of the top layer and the backing layer where the adhesive is located. For instance, the absorbent core can have a length and a width that are both shorter than the length and the width of the top layer and the backing layer. The adhesive can comprise a hydrophobic adhesive that is well suited for stopping the flow of liquids.

[0021] Other features and aspects of the present disclosure are discussed in greater detail below.

[0022] BRIEF DESCRIPTION OF THE DRAWINGS

[0023] A full and enabling disclosure of the present disclosure is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:

[0024] Figure 1 is a plan view of one embodiment of a pet mat made in accordance with the present disclosure;

[0025] Figure 2 is a cross-sectional view of the pet mat illustrated in Figure 1 ; and

[0026] Figure 3 is a plan view of the pattern of embossments incorporated into the pet mat illustrated in Figure 1 .

[0027] 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.

[0028] DEFINITIONS

[0029] As used herein, the term “conjugate fibers” refers herein to fibers which have been formed from at least two polymer sources extruded from separate extruders and spun together to form on fiber. Conjugate fibers are also sometimes referred to as bicomponent or multicomponent fibers. The polymers are arranged in substantially constantly positioned distinct zones across the cross-sections of the conjugate fibers and extend continuously along the length of the conjugate fibers. The configuration of such a conjugate fiber may be, for example, a sheath / core arrangement where one polymer is surrounded by another, or may be a side-by-side arrangement, a pie arrangement, or an “islands-in-the-sea” arrangement. Conjugate fibers are taught by U.S. Pat. No. 5,108,820 to Kaneko, et al., U.S. Pat. No. 4,795,668 to Krueger, et al., U.S. Pat. No. 5,540,992 to Marcher, et al., U.S. Pat. No. 5,336,552 to Strack, et al., U.S. Pat. No. 5,425,987 to Shawver, and U.S. Pat. No. 5,382,400 to Pike, et al., each being incorporated herein in their entirety by reference thereto for all purposes. For two component fibers, the polymers may be present in ratios of 75 / 25, 50 / 50, 25 / 75 or any other desired ratio. Additionally, polymer additives such as processing aids may be included in each zone.

[0030] As used herein, 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.

[0031] As used herein, the term “meltblown web” refers herein to a nonwoven web that is formed by a process in which a molten thermoplastic material is extruded through a plurality of fine, usually circular, die capillaries as molten fibers into converging high velocity gas (e.g., air) streams that attenuate the fibers of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly disbursed meltblown fibers. Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 to Buten, et al., which is incorporated herein in its entirety by reference thereto for all purposes. Generally speaking, meltblown fibers may be microfibers that are substantially continuous or discontinuous, generally smaller than 10 microns in diameter, and generally tacky when deposited onto a collecting surface.

[0032] As used herein, 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. The basis weight of nonwoven webs may generally vary, such as, from about 5, 10, or 20 gsm to about 120, 125, or 150 gsm.

[0033] As used herein, 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. Pat. No. 4,340,563 to Appel, et al., U.S. Pat. No. 3,692,618 to Dorschner, et al., U.S. Pat. No. 3,802,817 to Matsuki, et al., U.S. Pat. No. 3,338,992 to Kinney, U.S. Pat. No. 3,341 ,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartman, U.S. Pat. No. 3,502,538 to Levy, U.S. Pat. No. 3,542,615 to Dobo, et al., and U.S. Pat. No. 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 not tacky when they are deposited onto a collecting surface. Spunbond fibers may sometimes have diameters less than about 40 microns, and often between about 5 to about 20 microns. As used herein, the terms "superabsorbent polymer,” "superabsorbent, ” or "SAP” 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 articles in particle or fibrous form or as a coating or another material or fiber.

[0034] The term "pulp" as used herein refers to fibers from natural sources such as woody and non- woody plants. Woody plants include, for example, deciduous and coniferous trees. Non-woody plants include, for example, cotton, flax, esparto grass, milkweed, straw, jute, hemp, and bagasse. Pulp fibers can include hardwood fibers, softwood fibers, and mixtures thereof.

[0035] As used herein "bonded carded webs" refer to nonwoven webs formed by carding processes as are known to those skilled in the art and further described, for example, in U.S. Pat. No. 4,488,928 to Ali Khan et al., which is incorporated herein by reference thereto. Briefly, carding processes involve starting with a blend of, for example, staple fibers with binder fibers or other bonding components in a bulky ball that is combed or otherwise treated to provide a generally uniform basis weight. This web is heated or otherwise treated to activate the adhesive component resulting in an integrated, usually lofty nonwoven material.

[0036] As used herein, the term "hydrophilic" generally refers to fibers or films, or the surfaces of fibers or films that are wettable by aqueous liquids in contact with the fibers. The term "hydrophobic" includes those materials that are not hydrophilic as defined. The phrase "naturally hydrophobic" refers to those materials that are hydrophobic in their chemical composition state without additives or treatments affecting the hydrophobicity.

[0037] DETAILED DESCRIPTION

[0038] It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present disclosure.

[0039] In general, the present disclosure is directed to a liquid absorbent pet mat. The liquid absorbent pet mat of the present disclosure includes various features that each allow for excellent fluid management and control. The pet mat of the present disclosure, for instance, is designed to rapidly intake liquids, capture and hold the liquids within the product, and / or prevent liquids from leaking through the sides of the mat.

[0040] The pet mat of the present disclosure can have a multi-layer construction in which each layer has a particular function and different purpose. In one aspect, the pet mat includes a pattern of embossments that form absorbent containment areas on the mat. The pattern of embossments facilitate fluid intake rates and ensure that liquids absorbed by the mat are contained and trapped within the product. The pattern of embossments also can be used to ensure that the liquid absorbent materials contained in the mat do not migrate or move during shipping, storing, or handling of the mat. In this manner, the pattern of embossments ensures that the liquid absorbent material is distributed throughout the mat for absorbing and entrapping liquids and for preventing liquids from side leakage.

[0041] In addition, the pet mat can include a perimeter margin area that, in one embodiment, does not contain the liquid absorbent material. The perimeter margin area can be produced by attaching two layers of the mat together with an adhesive, such as a hydrophobic adhesive. In this manner, the perimeter margin area of the mat serves to block liquids from escaping out the side of the mat.

[0042] As described above, the pet mat of the present disclosure can have excellent fluid handling properties. For instance, the pet mat of the present disclosure can display a fluid intake rate of less than about 24 seconds, such as less than about 22 seconds, such as less than about 20 seconds. The fluid intake rate is generally greater than about 5 seconds. In addition to a very fast fluid intake rate, the pet mat of the present disclosure can also be constructed to have a relatively high liquid saturation capacity. For instance, the saturation capacity of the pet mat can be greater than about 0.3 g / cm2, such as greater than about 0.32 g / cm2, such as greater than about 0.34 g / cm2, such as greater than about 0.36 g / cm2, and generally less than about 0.8 g / cm2.

[0043] Referring to FIG. 1 , one embodiment of a pet mat 10 made in accordance with the present disclosure is shown. Referring to FIG. 2, a cross-sectional view of the pet mat 10 as illustrated in FIG. 1 is shown. Referring to FIG 2, the pet mat 10 includes a liquid permeable top layer 12 attached to a liquid impermeable backing layer 14. Contained between the top layer 12 and the backing layer 14 is an absorbent core 16. The absorbent core 16 contains a liquid absorbent material, such as a superabsorbent material. In one aspect, the absorbent core 16 can comprise a single layer of material containing the superabsorbent material. Alternatively, the absorbent core can comprise a multi-layer structure as shown in FIG. 2. For instance, the absorbent core 16 can include a first layer 18 comprising a tissue web that supports a second layer 20 comprising a superabsorbent material. Optionally, the absorbent core 16 can further include a third layer 22. The third layer 22 can comprise, for instance, a surge layer. The surge layer 22, for instance, can provide the pet mat with faster fluid intake and better dryness. The surge layer 22, for instance, can be capable of rapidly absorbing liquids and transferring the liquids to the absorbent core 16 that is designed to store and entrap the liquids and odors. The surge layer 22, for instance, can have fluid handling properties that can effectively disperse liquids that hit and saturate a particular target insult area. The surge layer 22 can increase the capability of the pet mat to move liquid away from the target insult area in order to limit saturation and improve the overall fluid handling performance of the product.

[0044] As shown in FIG. 1 , the absorbent core 16, in one aspect, can have a length and width that are less than the length and width of the top layer 12 and the backing layer 14. In this manner, the absorbent core 16 is enveloped between the top layer 12 and the backing layer 14.

[0045] For instance, the top layer 12 and the backing layer 14 can comprise a perimeter margin area 24. The top layer 12 and the backing layer 14 can be attached together over the perimeter margin 24. For example, as shown in FIG. 2, the top layer 12 and the backing layer 14 can be attached directly together only around the perimeter margin 24. In one aspect, for instance, an adhesive can be used to attach the top layer 12 to the backing layer 14. The adhesive can be applied around the perimeter of the top layer 12 and the backing layer 14. The adhesive, for instance, can be applied continuously or discontinuously around the perimeter between the layers. In this manner, the top layer 12 and the backing layer 14 are attached together on all four sides as shown in FIG. 1.

[0046] In general, any suitable adhesive can be used to attach the top layer 12 to the backing layer 14. In one aspect, the adhesive can comprise a hydrophobic adhesive. For example, the adhesive can comprise a hot melt adhesive. In one aspect, the adhesive comprises a polyolefin or a polyamide.

[0047] Attaching the top layer 12 to the backing layer 14 as shown in FIGS. 1 and 2 can provide various benefits and advantages. In particular, the perimeter margin 24 as shown in FIG. 1 serves as a liquid barrier and prevents liquids from migrating out the edges of the product. Attaching the top layer 12 to the backing layer 14 on all four sides of the pet mat also produces a consolidated product that is easy to handle. In addition, the perimeter margin 24 improves the aesthetic appeal of the product serving as a frame-like member for the pattern of embossments 26 applied to the absorbent core 16.

[0048] As shown in FIG. 1 , the pet mat 10 of the present disclosure includes a pattern of embossments 26. The pattern of embossments 26 are applied to at least the absorbent core 16. For instance, the pattern of embossments 24 can be applied to the absorbent core 16 alone or in combination with the top layer 12. Alternatively, the entire pet mat 10 can be embossed together. In one aspect, the absorbent core 16 is embossed alone or in combination with the backing layer 14 and then attached to the top layer 12 using a hydrophilic adhesive. The top layer 12 is pulled into the embossed areas during lamination. The pattern of embossments 26 are not only highly aesthetic but also serve to improve the fluid handling properties of the pet mat 10. For instance, the pattern of embossments 26 prevent migration of the liquid absorbent materials contained in the absorbent core 16 and can provide pockets for quickly absorbing liquids and retaining them within the pet mat 10. In accordance with the present disclosure, the pattern of embossments also includes open areas that increase fluid intake rates.

[0049] The pattern of embossments 26 can be described as depressions formed into at least the absorbent core 16 due to deformations of the layer(s) of the pet mat 10. The pattern of embossments 26 can have any suitable pattern to not only create an aesthetically pleasing surface, but also to facilitate funneling of liquids, such as pet urine, within a desired location of the pet mat 10. The pattern of embossments 26 can be formed using any known conventional technique. Suitable techniques include, for example, the use of raised elements to impart the desired embossing pattern into the absorbent core 16. For instance, a suitable process may include passing at least the absorbent core 16 through two rolls, including an engraved pattern roll opposite a smooth anvil roll. The engraved pattern roll, for instance, may comprise a steel roll, while the opposing roll can comprise a rubber roll. One or both rolls may be heated. Sufficient pressure can be applied for forming the pattern of embossments 26 into the absorbent core 16. In one aspect, sufficient pressure is applied to the absorbent core that causes the absorbent core 16 to mechanically attach together and densify where the embossments are applied. For instance, as shown in FIG. 2, one embossment 28 is illustrated. Where the embossments are located, the absorbent core 16 becomes densified and causes the layers to attach together. The attachment can be purely mechanical. In one aspect, the attachment may comprise fiber entanglement. Alternatively, heat and / or ultrasonic energy can be used in order to form thermal bonds or ultrasonic bonds where the embossments are located.

[0050] One particular pattern of embossments 26 is shown in FIGS. 1 and 3 in accordance with the present disclosure. Referring to FIG. 3, for instance, the pattern of embossments 26 can be comprised of line elements. The line elements can be continuous or discontinuous. In one aspect, the pattern of embossments 26 includes line elements 30 that comprise continuous line elements that extend over the entire width of the absorbent core 16. In the embodiment illustrated in FIG. 3, the line elements 30 extend in the width direction. Alternatively, however, the line elements 30 can extend in the length direction. In the embodiment illustrated, the line elements 30 have a wave-like shape. In addition, the line elements 30 are arranged in pairs that are spaced apart along the length of the absorbent core 16. Each pair of line elements can include intersecting points that form containment areas 32. The containment areas 32 prevent the liquid absorbent material, such as superabsorbent material, from migrating and moving within the absorbent core 16. The containment areas 32 not only prevent the liquid absorbent material in the absorbent core 16 from moving or migrating, but also provide areas where liquids are absorbed and entrapped. The containment areas 32 can also prevent liquids from moving to the edges of the pet mat 10.

[0051] In addition to the line elements 30 that extend over the length or width of the absorbent core 16, as shown in FIGS. 1 and 3, the line elements can also form discrete shapes. For instance, in the embodiment illustrated in FIG. 3, the line elements form dog paws 34. Each dog paw includes a heel portion 36 and a plurality of toe portions 38. Thus, each dog paw 34 actually creates five discrete shapes within the absorbent core 16. In addition, dog paws 34 of different sizes are incorporated into the pattern. In this manner, the pattern of embossments 26 includes discrete shapes of all different sizes that each form containment areas 32. It is believed that having containment areas 32 of different sizes not only enhances the overall appearance of the product but also provides for better fluid control. In the embodiment illustrated in FIG. 3, the containment areas 32 have at least five different sizes, such at least six different sizes, such as at least seven different sizes, and generally less than about fifteen different sizes. The containment areas are surrounded by open areas. In one aspect, the total area of the containment areas are minimized in order to improve liquid intake rates.

[0052] As shown in FIG. 3, the area of each containment area 32 can vary widely. The pattern can include large containment areas, medium-size containment areas, and small containment areas. The large containment areas, for instance, can have an area of greater than about 1 .5 cm2, such as greater than about 1 .8 cm2, such as greater than about 2 cm2, such as greater than about 2.3 cm2, such as greater than about 2.5 cm2, such as greater than about 2.8 cm2, such as greater than about 3 cm2, such as greater than about 3.2 cm2, and less than about 8 cm2, such as less than about 6 cm2. The medium-size containment areas, on the other hand, can have an area of from about 0.5 cm2to about 1 .5 cm2. For instance, the medium-size containment areas can have an area of greater than about 0.7 cm2, such as greater than about 0.9 cm2, such as greater than about 1.1 cm2.

[0053] The small containment areas, on the other hand, can have an area of less than about 0.5 cm2, such as less than about 0.4 cm2, such as less than about 0.3 cm2, and greater than about 0.08 cm2, such as greater than about 0 1 cm2, such as greater than about 0.12 cm2.

[0054] As shown in FIG. 3, the containment areas 32 of the pattern of embossments 26 are surrounded by open areas 40. The amount of open areas versus the amount of containment areas can vary depending upon many factors, including the size of the pet mat, the type of liquid absorbent material contained in the pet mat, the construction of the absorbent core, and the like. In general, the containment areas occupy greater than about 10%, such as greater than about 15%, such as greater than about 20%, such as greater than about 25%, such as greater than about 30%, such as greater than about 40%, such as greater than about 45%, such as greater than about 50%, such as greater than about 55% of the surface area of the absorbent core 16. The containment areas generally occupy less than about 75%, such as less than about 70%, such as less than about 65%, such as less than about 60%, such as less than about 45%, such as less than about 40%, such as less than about 35% of the surface area of the absorbent core 16. The open areas can comprise greater than about 20%, such as greater than about 30%, such as greater than about 35%, such as greater than about 40%, such as greater than about 45%, such as greater than about 50%, such as greater than about 55%, such as greater than about 60%, such as greater than about 65% of the surface area of the absorbent core 16. The open areas generally occupy less than about 90%, such as less than about 85%, such as less than about 80%, such as less than about 75%, such as less than about 70%, such as less than about 65%, such as less than about 60%, such as less than about 55%, such as less than about 50%, such as less than about 45% of the surface area of the absorbent core 16.

[0055] The overall dimensions of the pet mat can also vary depending upon the particular application. In one embodiment, for instance, the pet mat can have a width of greater than about 18 inches, such as greater than about 20 inches, such as greater than about 24 inches, such as greater than about 28 inches, such as greater than about 30 inches, such as greater than about 34 inches. The width can generally be less than about 60 inches, such as less than about 50 inches, such as less than about 45 inches, such as less than about 40 inches, such as less than about 38 inches. The pet mat can have a length that is greater or less than the size of the width. The length can also be greater than about 18 inches, such as greater than about 20 inches, such as greater than about 24 inches, such as greater than about 28 inches, such as greater than about 30 inches, such as greater than about 34 inches. The length can generally be less than about 60 inches, such as less than about 50 inches, such as less than about 45 inches, such as less than about 40 inches, such as less than about 38 inches.

[0056] As described above and as shown in FIG. 2, the pet mat 10 includes a liquid permeable top layer 12, an absorbent core 16, and a liquid impermeable backing layer 28.

[0057] Top Layer:

[0058] The top layer 12 is liquid permeable, can be hydrophilic, and desirably retains little to no liquid in its structure. The top layer 12 can be a single layer of material, or alternatively, can be multiple layers that have been laminated together. The top layer 12 can be constructed of any material such as one or more woven sheets, one or more fibrous nonwoven sheets, one or more film sheets, such as blown or extruded films, which may themselves be of single or multiple layers, one or more foam sheets, such as reticulated, open cell or closed cell foams, a coated nonwoven sheet, or a combination of any of these materials. Such combination can be adhesively, thermally, or ultrasonically laminated into a unified planar sheet structure to form a top layer 12. In various embodiments, the top layer 12 can be constructed from various nonwoven webs such as meltblown webs, spunbond webs, hydroentangled spunlace webs, or through air bonded carded webs. Examples of suitable top layer 12 materials can include, but are not limited to, natural fiber webs (such as cotton), rayon, hydroentangled webs, bonded carded webs of polyester, polypropylene, polyethylene, nylon, or other heat-bondable fibers (such as bicomponent fibers), polyolefins, copolymers of polypropylene and polyethylene, linear low-density polyethylene, and aliphatic esters such as polylactic acid. Finely perforated films and net materials can also be used, as can laminates of / or combinations of these materials. An example of a suitable top layer 12 can be a bonded carded web made of polypropylene and polyethylene such as that obtainable from Sandler Corp., Germany. U.S. Pat. No. 4,801 ,494 to Datta, et al., and U.S. Pat. No. 4,908,026 to Sukiennik, et al., and WO 2009 / 062998 to Texol teach various other topsheet materials that may be used as the top layer 12, each of which is hereby incorporated by reference thereto in its entirety. Additional top layer 12 materials can include, but are not limited to, those described in U.S. Pat. No. 4,397,644 to Matthews, et al., U.S. Pat. No. 4,629,643 to Curro, et al., U.S. Pat. No. 5,188,625 to Van Iten, et al., U.S. Pat. No. 5,382,400 to Pike, et al., U.S. Pat. No. 5,533,991 to Kirby, et al., U.S. Pat. No. 6,410,823 to Daley, et al., and U.S. Publication No. 2012 / 0289917 to Abuto, et al., each of which is hereby incorporated by reference thereto in its entirety.

[0059] In various embodiments, the top layer 12 may contain a plurality of apertures formed therethrough to permit liquid, such as pet urine, to pass more readily into the absorbent core 16. The apertures may be randomly or uniformly arranged throughout the top layer 12.

[0060] In various embodiments, the top layer 12 can have a basis weight ranging from about 5, 10, 15, 20, or 25 gsm to about 50, 100, 120, 125, or 150 gsm. For example, in an embodiment, a top layer 12 can be constructed from a through air bonded carded web having a basis weight ranging from about 5 gsm to about 20 gsm, such as from about 7 gsm to about 15 gsm. In various embodiments, the top layer 12 can be at least partially or completely hydrophilic.

[0061] In various embodiments, the top layer 12 can be a multicomponent top layer 12 such as by having two or more different nonwoven or film materials, with the different materials joined together.

[0062] In one aspect, the top layer 12 can comprise a spunbond material. Such a spunbond layer may be formed from a polyester or a polyolefin, such as a polypropylene and can include a wetting agent if desired. In various embodiments, a spunbond layer can have a basis weight from about 5 or 7 gsm to about 20 or 30 gsm and can be treated with hydrophilic wetting agents.

[0063] Absorbent Core:

[0064] An absorbent core 16 can be positioned between the top layer 12 and the backing layer 14 of the pet mat 10. The absorbent core 16 can generally be any single layer structure or combination of layer components, which can demonstrate some level of compressibility, conformability and capability of absorbing and retaining liquids, such as pet urine or other body fluids. In various embodiments, the absorbent core 16 can be formed from a variety of different materials and can contain any number of desired layers. For example, the absorbent core 16 can include one or more layers (e.g., two layers) of absorbent web material of cellulosic fibers (e.g., wood pulp fibers), other natural fibers, synthetic fibers, woven or nonwoven sheets, scrim netting, or other stabilizing structures, superabsorbent material, binder materials, surfactants, selected hydrophobic and hydrophilic materials, pigments, lotions, odor control agents or the like, as well as combinations thereof. In an embodiment, the absorbent web material can include a matrix of cellulosic fluff combined with a superabsorbent material. The cellulosic fluff can comprise a blend of 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.

[0065] In various embodiments, if desired, the absorbent core 16 can include an amount of superabsorbent material. Examples of suitable superabsorbent material can include poly(acrylic acid), poly(methacrylic acid), poly(acrylamide), poly(vinyl ether), maleic anhydride copolymers with vinyl ethers and o-olefins, poly(vinyl pyrrolidone), poly(vinylmorpholinone), poly(vinyl alcohol), and salts and copolymers thereof. Other superabsorbent materials can include unmodified natural polymers and modified natural polymers, such as hydrolyzed acrylonitrile-grafted starch, acrylic acid grafted starch, methyl cellulose, chitosan, carboxymethyl cellulose, hydroxypropyl cellulose, and natural gums, such as alginates, xanthan gum, locust bean gum, and so forth. Mixtures of natural and wholly or partially synthetic superabsorbent polymers can also be useful. The superabsorbent material can be present in the absorbent core 16 in any amount as desired.

[0066] Regardless of the combination of absorbent materials used in the absorbent core 16, the absorbent materials can be formed into a web structure by employing various conventional methods and techniques. For example, the absorbent web can be formed by techniques such as, but not limited to, a dry-forming technique, an air forming technique, a wet forming technique, a foam forming technique, or the like, as well as combinations thereof. A coform nonwoven material can also be employed. Methods and apparatus for carrying out such techniques are well known in the art.

[0067] By way of example, suitable materials and / or structures for the absorbent core 16 can include, but are not limited to, those described in U.S. Pat. No. 4,610,678 to Weisman, et al., U.S. Pat. No. 6,060,636 to Yahiaoui, et al., U.S. Pat. No. 6,610,903 to Latimer, et al., U.S. Pat. No. 7,358,282 to Krueger, et al., and U.S. Publication No. 2010 / 0174260 to Di Luccio, et al. each of which is hereby incorporated by reference thereto in its entirety. In one aspect, the absorbent core 16 can be a single layer structure and can include, for example, a matrix of cellulosic fluff and superabsorbent material. Alternatively, the absorbent core 16 can have at least two layers of material, such as, for example, a top facing layer and a bottom facing layer. In various embodiments, the two layers can be identical to each other. In various embodiments, the two layers can be different from each other. In such embodiments, the two layers can provide the pet mat 10 with different absorption properties as deemed suitable. In various embodiments, the top facing layer of the absorbent core 16 may be constructed of an airlaid material and the bottom facing layer of the absorbent core 16 may be constructed of a superabsorbent polymer-containing compressed sheet. In such embodiments, the airlaid material can have a basis weight from about 30 to about 100 gsm and the superabsorbent polymer-containing compressed sheet can be a cellulosic fluff based material that can be a combination of cellulosic pulp and SAP enclosed with a tissue carrier and having a basis weight from about 10 to about 70 gsm.

[0068] In the embodiment illustrated in FIG. 2, the absorbent core 16 comprises a first layer 18 and a second layer 20. The second layer 20 can comprise a superabsorbent material alone or in combination with cellulose fluff. In one embodiment, for instance, the second layer 20 can have a basis weight of from about 30 gsm to about 100 gsm, such as from about 40 gsm to about 80 gsm. The second layer 20 can contain a superabsorbent material in an amount from about 15 gsm to about 35 gsm and can contain cellulose fluff in an amount from about 25 gsm to about 45 gsm. The first layer 18, on the other hand, can comprise a tissue carrier web. The tissue web, for instance, can have a basis weight of from about 10 gsm to about 20 gsm, such as from about 12 gsm to about 15 gsm. The tissue web not only supports the second layer 20 but can also help increase the saturation capacity of the product.

[0069] Liquid Impermeable Backing Layer:

[0070] The backing layer 14 is generally liquid impermeable. The backing layer 14 can permit the passage of air or vapor out of the pet mat 10 while still blocking the passage of liquids. Any liquid impermeable material may generally be utilized to form the backing layer 14. The backing layer 14 can be composed of a single layer or multiple layers, and these one or more layers can themselves comprise similar or different materials. Suitable material that may be utilized can be a microporous polymeric film, such as a polyolefin film or polyethylene or polypropylene, nonwovens, and nonwoven laminates, and film / nonwoven laminates. The particular structure and composition of the backing layer 14 can be selected from various known films and / or fabrics with the particular material being selected as appropriate to provide the desired level of liquid barrier, strength, abrasion resistance, tactile properties, aesthetics, and so forth. In various embodiments, a polyethylene film can be utilized that can have a thickness in the range of from about 0.2 or 0.5 mils to about 3.0 or 5.0 mils. An example of a backing layer 14 can be a polyethylene film such as that obtainable from Pliant Corp., Schaumburg, III., USA. Another example can include calcium carbonate-filled polypropylene film. In still another embodiment, the backing layer 14 can be a hydrophobic nonwoven material with water barrier properties such as a nonwoven laminate, an example of which can be a spunbond, meltblown, meltblown, spunbond, four-layered laminate. In one aspect, the backing layer can be a polymer film that is non-breathable and has a basis weight of from about 18 gsm to about 24 gsm.

[0071] In various embodiments, the backing layer 14 can be a two layer construction, including an outer layer material and an inner layer material which can be bonded together. The outer layer can be any suitable material and may be one that provides a generally cloth-like texture or appearance to the wearer. An example of such material can be a 100% polypropylene bonded-carded web with a diamond bond pattern available from Sandler A. G., Germany, such as 30 gsm Sawabond 4185® or equivalent. Another example of material suitable for use as an outer layer can be a 17 gsm to 23 gsm spunbond polypropylene non-woven web. The inner layer can be either vapor permeable (i.e., "breathable”) or vapor impermeable. The inner layer may be manufactured from a thin plastic film, although other liquid impermeable materials may also be used. The inner layer can inhibit liquids from leaking out of the pet mat 10. An example of a material for an inner layer can be a printed 19 gsm Berry Plastics XP-8695H film or equivalent commercially available from Berry Plastics Corporation, Evansville, Ind., U S A

[0072] The backing layer 14 can, therefore, be of a single or multiple layer construction, such as of multiple film layers or laminates of film and nonwoven fibrous layers. Suitable backing layers 14 can be constructed from materials such as those described in U.S. Pat. No. 4,578,069 to Whitehead, et al., U.S. Pat. No. 4,376,799 to Tusim, et al., U.S. Pat. No. 5,695,849 to Shawver, et al., U.S. Pat. No. 6,075,179 to McCormack, et al., and U.S. Pat. No. 6,376,095 to Cheung, et al., each of which are hereby incorporated by reference thereto in its entirety.

[0073] Surge Layer:

[0074] In various embodiments, the pet mat 10 can optionally have a surge layer 22 in fluid communication with the top layer 12. For example, the surge layer 22 can be positioned between the top layer 12 and the absorbent core 16.

[0075] In various embodiments, the surge layer 22 can be made of a material that can be capable of transferring, in the depth direction (Z), liquids that are delivered to the top layer 12. Any of a variety of materials can be utilized as the surge layer 22. In various embodiments, the material can be synthetic, cellulosic, or a combination of synthetic and cellulosic materials. In various embodiments, the surge layer 22 can be constructed from woven or nonwoven materials. For example, the surge layer 22 can be constructed as an airlaid or a TABCW material. For example, airlaid cellulosic tissues may be suitable for use in the surge layer 22. The airlaid cellulosic tissue may have a basis weight ranging from about 10 or 12 gsm to about 30 or 50 gsm. The airlaid cellulosic tissue can be formed from hardwood and / or softwood fibers. An airlaid cellulosic tissue can have a fine pore structure and can provide an excellent wicking capacity.

[0076] In various embodiments, a foam material can be utilized to form the surge layer 22. In various embodiments, the foam material can be an open-cell or porous foam. The physical properties of the foam material as well as its wettability and fluid management properties can be tailored to meet the specific characteristics desired for the usage of a foam material in the pet mat 10. In various embodiments, the foam material can be moisture stable and not degrade or collapse and lose its structure and fluid management properties when exposed to liquids. In various embodiments, the foam material can be an open-cell foam, a closed cell foam, or a partially open-cell foam that is either a thermoplastic or thermoset material. A foam material can be manufactured by extrusion or casting and coating processes including frothed foam, aerated foam, and emulsion foam methods. Such foams can be manufactured from different polymer chemistries to achieve the desired softness, flexibility, and resilience of the foam material when utilized in a pet mat 10. In various embodiments, the foam material can be based on organic or inorganic chemistries and can also be based upon a foam material obtained from natural sources. In various embodiments, the foam material can have a polymer chemistry which can be a polyurethane foam, polyolefin foam, poly(styrene-butadiene) foam, poly(ethylene-vinyl acetate) foam, or a silicone based foam. Other polymer chemistries known to one of ordinary skill in the art could be used along with additives such as plasticizers, opacifiers, colorants, antioxidants, and stabilizers to obtain the desired foam properties. In various embodiments, the viscoelastic properties could be modified to obtain a desired response to applied load from the foam material including properties similar to that commonly referred to as polyurethane memory foam materials. In various embodiments, the Poisson's ratio of the foam material could be modified to obtain the desired response from the foam material to applied stress and foam materials with auxetic properties could be considered if desired.

[0077] A porous foam material can have pores which can vary in size and / or distribution. In various embodiments, a pore size of a foam material can be from about 10 microns to about 350 microns. In various embodiments, the foam material can have a multimodal pore size distribution in order to handle a variety of components within the body exudates. In various embodiments, a multimodal pore size distribution can be achieved within the same monolithic foam structure or could be achieved by using layers of foam material with a narrow pore size distribution which when combined into a single foam material would allow a multimodal pore size distribution to be achieved for the combination of layers. In various embodiments, the foam material can be a polyester polyurethane foam material. In various embodiments, the average cell size of the foam material can be from about 100, 150, or 200 microns to about 250, 300, or 350 microns. The number of open cells in the foam material can provide the foam material with measurement of the foam material's porosity. The porosity of the foam material is measured in pores per linear inch (ppi) and refers to the number of pores in one linear inch of a two- dimensional planar foam material surface and is described by the Polyurethane Foam Association. The pores per linear inch is measured by counting the pores visually under a microscope using a grid. The smaller the ppi value of the foam material the larger the pore size, and vice versa. In various embodiments, the foam material can have a porosity from about 20 or 40 ppi to about 55, 65, or 90 ppi. In various embodiments in which an open-cell foam material is utilized, the foam material can be substantially open-cell or of a completely reticulated structure. The reticulation of the foam material can be achieved by several methods known to one skilled in the art include foam made by in-situ reticulation processes during foam formation. The reticulated foam material can also be made by treating a substantially open-cell foam material to a high pressure fluid stream to remove the cell walls of the foam material.

[0078] The foam material can be either hydrophilic or hydrophobic dependent upon the desired properties of the foam material in the pet mat 10. In various embodiments the foam material can be a hydrophilic foam material. In various embodiments, the foam material can be hydrophobic and can be treated with a surfactant to create a hydrophilic foam material. In various embodiments, for example, the material utilized to form the surge layer 22 can be a hydrophobic, open-cell, polyurethane foam treated with from about 0.3% or 0.8% to about 1 .6, 2.0, or 3.0% of a surfactant. In various embodiments, the surfactant utilized to treat the foam material can be a nonionic surfactant such as a nonionic surfactant comprising at least an ethoxylated linear oleochemical alcohol such as an alkylphenol ethoxylate, such as LUTENSOL® A65N, commercially available from BASF, or an ethoxylated acetylenic diol such as SURFYNOL® 465, commercially available from Air Products, Allentown, Pa.

[0079] In one aspect, the surge layer 22 can comprise a nonwoven web, such as a bonded carded web. In one aspect, the bonded carded web can by through-air bonded. The nonwoven web, for instance, can include staple fibers and binder fibers. In producing a carded web, bales of the fibers can be placed in contact with a picker which separates the fibers. Next, the fibers are fed through a combing or carding unit which further breaks apart and optionally aligns the fibers along a direction. Once the web is formed, the web is then bonded using one or more bonding methods. In one aspect, the carded web can be bonded using through-air bonding. Through-air bonding, for instance, controls the level of compression or collapse of the nonwoven web during the bonding process. The nonwoven web can further include a hydrophilic treatment. The hydrophilic treatment can comprise a polyethylene glycol laurate, a polyethylene glycol lauryl ether, or combinations thereof. The nonwoven web can have a basis weight of from about 10 gsm to about 30 gsm, such as from about 12 gsm to about 25 gsm.

[0080] The pet mat 10 can have an overall basis weight that is relatively low. For instance, the basis weight of the pet mat 10 can be less than about 300 gsm, such as less than about 200 gsm, such as less than about 180 gsm, such as less than about 160 gsm, such as less than about 140 gsm. The basis weight of the pet mat 10 can be greater than about 50 gsm, such as greater than about 70 gsm, such as greater than about 90 gsm, such as greater than about 100 gsm, such as greater than about 110 gsm.

[0081] As shown in FIG. 1, the pet mat 10 has a flat planar structure The pet mat 10 can be constructed without including any fasteners, side panels, elastic members, or the like.

[0082] When constructing the pet mat 10, the different layers can be adhered together using a hydrophilic adhesive. In one aspect, for instance, the absorbent core 16 is produced and adhered to the top layer 12 using a hydrophilic adhesive. The resulting structure can then be embossed and placed on the backing layer 14. Adhesive can be applied to the backing layer for producing the perimeter margin 24. Individual sheets can then be cut and the product can be packaged.

[0083] The present disclosure may be better understood with reference to the following examples.

[0084] Examples

[0085] Test Procedures

[0086] As used herein, the liquid intake rate is determined as follows. A separatory funnel is placed in a ring stand with a 2” diameter and positioned 5 cm from a countertop. 50 ml_ of saline solution (0.9% (w / w) aqueous isotonic saline solution) is poured into the funnel. The valve on the funnel is opened and the flow rate is verified to be 6.7 ± 3 mL / sec.

[0087] Weigh a pet map to be tested and lay the mat flat on the counter. Place the bottom of the funnel over a center point on the mat. Add 100 mL of saline solution into the empty funnel. The saline solution can be colored blue if desired. The valve of the funnel is opened and a stopwatch is started simultaneously. Stop the stopwatch after all of the fluid on the surface of the mat is absorbed. Record the intake time in seconds and discard the pet mat.

[0088] As used herein, the liquid saturation capacity of the pet mat is determined as follows. The saturation capacity test is similar to the test described in WO 2022 / 182961 which is incorporated herein by reference and is measured according to the following protocol. Specimens were prepared to the following dimensions: 1 .88" in length and 1 .88” in width. The specimens were sealed in a spunbond nonwoven bag prior to the test to prevent material loss due to SAM swelling during the test. The spunbond nonwoven bag was made from a 12 gsm spunbond material cut into 6”x6” squares. The material was folded over and two of the open sides were sealed to create the bag. The saturation capacity test was performed using a table top saturation capacity tester as described herein. First, the dry sample mass is measured. Then, the samples were saturated for 20 minutes in a saline solution (0.9 wt% NaCI) and then allowed to drip dry for 1 minute. The samples were next placed on the mesh screen of the table top saturation capacity tester having 0.25 inch (6.4 mm) openings (commercially available from Taconic Plastics Inc. Petersburg, N.Y.) which, in turn, is placed on a vacuum box and covered with a flexible rubber dam material, such as a latex sheet. A vacuum of 3.5 kilopascals (0.5 pounds per square inch) is drawn in the vacuum box for a period of 5 minutes. The sample is then removed from the vacuum box and weighed against to determine a saturated, or wet weight of the sample. If material, such as superabsorbent material or fiber, is drawn through the fiberglass screen while on the vacuum box, a screen having smaller openings should be used. Alternatively, a piece of the tea bag material (such as heat sealable tea bag material (grade 542, commercially available from the Kimberly-Clark Corporation)) can be placed between the material and the screen and the final value adjusted for the fluid retained by the tea bag material. The saturation capacity is the total weight of the wet sample minus the sample dry weight. The results can be converted to mass per area of absorption.

[0089] Example 1

[0090] A pet mat was made in accordance with the present disclosure and tested for fluid intake rate and for saturation capacity. The pet mat included a top layer comprising a spunbond hydrophilic nonwoven covering an absorbent core comprised of a surge layer, a liquid absorbent layer, and a tissue layer. The liquid absorbent layer contained a superabsorbent material combined with cellulose fluff. The backing layer comprised a non-breathable polymer film. The pet mat was as described above and as shown in FIG. 1 .

[0091] When tested according to the fluid intake rate test, the following results were obtained:

[0092] Pet mats as described above were also tested for saturation capacity. The following results were obtained:

[0093] As shown above, not only did the product display very quick intake rates but also displayed saturation capacities greater than 0.3 g / cm2.

[0094] 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.

Claims

What Is Claimed:1 . A liquid absorbent pet mat comprising a multi-layer planar structure comprising: a top liquid permeable layer attached to a liquid impermeable backing layer along a perimeter of the pet mat; an absorbent core contained between the top layer and the backing layer, the absorbent core comprising a superabsorbent material; and a pattern of embossments formed into at least the absorbent core, the pattern of embossments comprising line elements that form containment areas for the superabsorbent material.2 A liquid absorbent pet mat as defined in claim 1 , wherein the line elements extend over a length or a width of the absorbent core.

3. A liquid absorbent pet mat as defined in any of the preceding claims, wherein the line elements are continuous.

4. A liquid absorbent pet mat as defined in any of the preceding claims, wherein the pattern of embossments includes pairs of line elements that extend over a length or a width of the absorbent core, the pairs of line elements intersect to form containment areas.

5. A liquid absorbent pet mat as defined in claim 1 , wherein the line elements form discrete shapes, each discrete shape comprising a containment area, the discrete shapes having different sizes.

6. A liquid absorbent pet mat as defined in any of the preceding claims, wherein the containment areas are surrounded by open areas and wherein the absorbent core has a surface area and wherein the containment areas comprise from about 10% to about 60% of the surface area, such as from about to about 15% to about 50% of the surface area, and the open areas comprise from about 40% to about 90% of the surface area, such as from about 50% to about 85% of the surface area.

7. A liquid absorbent pet mat as defined in claim 4, wherein each pair of line elements have a wave-like shape and wherein the pairs of line elements all extend in the same direction and are spaced apart over a surface of the absorbent core.

8. A liquid absorbent pet mat as defined in claim 4 or 7, wherein the line elements further form discrete shapes, the discrete shapes being positioned in between the line elements that extend over a length or a width of the absorbent core.

9. A liquid absorbent pet mat as defined in any of the preceding claims, wherein the absorbent core comprises a blend of the superabsorbent material with fluff cellulose fibers.

10. A liquid absorbent pet mat as defined in any of the preceding claims, wherein the absorbent core comprises at least two layers, the first layer comprising the superabsorbent material, the first layer being positioned on a second layer, the second layer comprising a tissue web.

11. A liquid absorbent pet mat as defined in claim 10, wherein the absorbent core further comprises a third layer positioned on top of the second layer, the third layer comprising a surge material.

12. A liquid absorbent pet mat as defined in any of the preceding claims, wherein the top liquid permeable layer comprises a spunbond web.

13. A liquid absorbent pet mat as defined in any of the preceding claims, wherein the superabsorbent material is contained within a layer within the absorbent core, the layer having a basis weight of from about 40 gsm to about 80 gsm.

14. A liquid absorbent pet mat as defined in any of the preceding claims, wherein the pet mat displays a fluid intake rate of less than about 24 seconds, such as less than about 22 seconds.

15. A liquid absorbent pet mat as defined in any of the preceding claims, wherein the pet mat displays a saturation capacity of greater than about 0.3 g / cm2, such as greater than about 0.32 g / cm2, such as greater than about 0.34 g / cm2.

16. A liquid absorbent pet mat as defined in any of the preceding claims, wherein the top layer and the backing layer are attached together by an adhesive, the adhesive only being located along a perimeter of the top layer and the back layer, the adhesive extending around the entire perimeter, the adhesive directly attaching the top layer to the backing layer.

17. A liquid absorbent pet mat as defined in claim 16, wherein the absorbent core does not extend into a perimeter margin of the top layer and the back layer where the two layers are attached together.

18. A liquid absorbent pet mat as defined in claim 16 or 17, wherein the adhesive comprises a hydrophobic adhesive.

19. A liquid absorbent pet mat comprising a multi-layer planar structure comprising: a top liquid permeable layer attached to a liquid impermeable backing layer along a perimeter of the pet mat; an absorbent core contained between the top layer and the backing layer, the absorbent core comprising a superabsorbent material; and a pattern of embossments formed into at least the absorbent core, the pattern of embossments comprising line elements that extend over a length or over a width of the absorbent core, at least some of the line elements being spaced apart without intersecting.

20. A liquid absorbent pet mat as defined in claim 19, wherein the line elements are continuous and the pattern of embossments includes pairs of line elements spaced apart, each pair of line elements intersecting in order to form containment areas for the superabsorbent material.21 . A liquid absorbent pet mat as defined in claim 19 or 20, wherein the line elements further form discrete shapes in between the line elements that extend over the length or width of the absorbent core, the discrete shapes having different sizes.

22. A liquid absorbent pet mat as defined in claim 19, wherein the containment areas are surrounded by open areas and wherein the absorbent core has a surface area and wherein the containment areas comprise from about 10% to about 60% of the surface area, such as from about to about 15% to about 50% of the surface area, and the open areas comprise from about 40% to about 90% of the surface area, such as from about 50% to about 85% of the surface area.

23. A liquid absorbent pet mat as defined in claim 19, wherein the absorbent core comprises a blend of the superabsorbent material with fluff cellulose fibers.

24. A liquid absorbent pet mat as defined in claim 19, wherein the absorbent core comprises at least two layers, the first layer comprising the superabsorbent material, the first layer being positioned on a second layer, the second layer comprising a tissue web.

25. A liquid absorbent pet mat as defined in claim 19, wherein the absorbent core further comprises a third layer positioned on top of the second layer, the third layer comprising a surge material.

26. A liquid absorbent pet mat as defined in claim 19, wherein the top liquid permeable layer comprises a spunbond web.

27. A liquid absorbent pet mat as defined in claim 19, wherein the superabsorbent material is contained within a layer within the absorbent core, the layer having a basis weight of from about 40 gsm to about 80 gsm.

28. A liquid absorbent pet mat as defined in claim 19, wherein the pet mat displays a fluid intake rate of less than about 24 seconds, such as less than about 22 seconds.

29. A liquid absorbent pet mat as defined in claim 19, wherein the pet mat displays a saturation capacity of greater than about 0.3 g / cm2, such as greater than about 0.32 g / cm2, such as greater than about 0.34 g / cm2.

30. A liquid absorbent pet mat as defined in claim 19, wherein the top layer and the backing layer are attached together by an adhesive, the adhesive only being located along a perimeter of the top layer and the back layer, the adhesive extending around the entire perimeter, the adhesive directly attaching the top layer to the backing layer.31 . A liquid absorbent pet mat as defined in claim 30, wherein the absorbent core does not extend into a perimeter margin of the top layer and the back layer where the two layers are attached together.

32. A liquid absorbent pet mat as defined in claim 30 or 31 , wherein the adhesive comprises a hydrophobic adhesive.

33. A liquid absorbent pet mat comprising a multi-layer planar structure comprising: a top liquid permeable layer attached to a liquid impermeable backing layer along a perimeter of the pet mat; an absorbent core contained between the top layer and the backing layer, the absorbent core comprising a superabsorbent material; a pattern of embossments formed into at least the absorbent core; and wherein the top layer and the backing layer are attached together by an adhesive, the adhesive only being located along a perimeter of the top layer and the backing layer.

34. A liquid absorbent pet mat as defined in claim 33, wherein the adhesive extends around the entire perimeter of the top layer and backing layer.

35. A liquid absorbent pet mat as defined in claim 33 or 34, wherein the absorbent core does not extend into a perimeter margin of the top layer and the back layer where the two layers are attached together.

36. A liquid absorbent pet mat as defined any of claims 33-35, wherein the adhesive comprises a hydrophobic adhesive.

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