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

Abstract

An absorbent article includes a top sheet, a back sheet, and an absorbent core disposed between the top sheet and the back sheet. The absorbent core includes a superabsorbent layer with superabsorbent particles bonded together with an adhesive. A core wrap is disposed around the absorbent core. The core wrap contacts the top sheet.

Description

[0001] KCX-2165- PCT / 65131214PCT02

[0002] ABSORBENT CORE WITH A FLUID ABSORBTION LAYER AND A FLUID RESERVOIR LAYER

[0003] CROSS-REFERENCE TO RELATED APPLICATION

[0004] This application is related and has right of priority to U.S. Provisional Application No. 63 / 673,883, which was filed in the United States Patent & Trademark Office on July 22, 2024 and is incorporated by reference in its entirety.

[0005] BACKGROUND

[0006] Personal care products, such as diapers, diaper pants, training pants, adult incontinence products, and feminine care products, can include absorbent structures that are intended to provide various functional characteristics. For example, absorbent structures in such products are intended to intake body exudates sufficiently quickly, distribute such exudates to an absorbent core that is capable of storing an adequate volume of exudates, and prevent such stored exudates in the absorbent core from exiting the absorbent core and transferring to other layers of the product and / or against the user's skin or clothing.

[0007] Personal care products often include superabsorbent material (SAM) to help increase absorbent capacity. Absorbent structures must also balance other properties such as thickness (wet thickness and / or dry thickness), stiffness, and weight, and manufacturers are often seeking a more premium wear experience for wearers that provide flexible, lightweight absorbent articles, such as feminine care pads.

[0008] Thinner absorbent articles with quick liquid uptake and low rewet would be useful.

[0009] SUMMARY

[0010] In general, the present disclosure is directed to thin absorbent articles with features for providing desirable rewet and intake. The absorbent articles may include a top sheet and a back sheet. An absorbent core between the top sheet and the back sheet may be positioned in direct contact with the top sheet. Thus, e.g., a nonwoven core wrap around absorbent material of the core may be positioned on and contact the top sheet. Such arrangement of features may advantageously provide a thin absorbent article. In addition, properties of the top sheet and core wrap may be selected to provide the desired rewet, intake, and other properties. For instance, the core wrap may contain adhesive material during manufacturing and limit migration of the adhesive material out of the absorbent core. For example, the air permeability of the core wrap may be no greater than 954 CFM. The core wrap may also assist with transferring liquid exudates from the top sheet to the absorbent +materials within KCX-2165- PCT / 65131214PCT02 the core wrap. For instance, the core wrap may have a void volume no less than 0.08 cm3 / cm2and no greater than 0.12 cm3 / cm2, such as about 0.096 cm3 / cm2, to manage insult fluids. As another example, a thickness of the core wrap may be less than 1 mm to bring the top sheet close to the absorbent material within the core wrap for effective dewatering and reduction of rewet levels. The core wrap may also have a strike though of about 0.3 s to allow fast fluid transfer from the top sheet through the core wrap to the absorbent materials within the core. The absorbent core may also have a void volume to hold and manage insult fluid during absorption by the absorbent material. For instance, the absorbent core may have a void volume between 0.27 cm3 / cm2and 0.35 cm3 / cm2to create the space needed to manage the insult fluid entering the core.

[0011] The top sheet may also be configured to facilitate intake and rewet. The liquid strike through of the top sheet in combination with the void volume and permeability of the core wrap may collectively to assist with efficient transfer of fluid to the absorbent material in the core. The core wrap may have a void volume of 0.08 cm3 / cm2and no greater than 0.12 cm3 / cm2, such as about 0.096 cm3 / cm2, and a liquid strike though of about 0.3 s to allow the top sheet to have a range of strike through values that provide desired intake and rewet.

[0012] The absorbent core may have a horizontal side compression energy @ cycle 1 wet of less than 700 g*cm to provide a flexible feel.

[0013] In one example embodiment, an absorbent article, includes a top sheet, a back sheet, and an absorbent core disposed between the top sheet and the back sheet. The absorbent core includes a superabsorbent layer with superabsorbent particles bonded together with an adhesive. A core wrap is disposed around the absorbent core. The core wrap contacts the top sheet. A thickness of the absorbent article between the top sheet and the back sheet at the absorbent core is no less than two millimeters and no greater than four millimeters. A total absorbent capacity of the absorbent article is no less than one hundred grams. A pressurized rewet of the absorbent article is no less than five- hundredths gram and no greater than seventeen-hundredths gram.

[0014] In another example embodiment, an absorbent article includes a top sheet, a back sheet, and an absorbent core disposed between the top sheet and the back sheet. The absorbent core includes a superabsorbent layer with superabsorbent particles present within the superabsorbent layer at no less than ninety percent by weight of the superabsorbent layer. A core wrap is disposed around the absorbent core. The core wrap contacts the top sheet layer. An intake time of the absorbent article is no less than four seconds and no greater than six seconds. A water contact angle to the top sheet layer is greater than ninety degrees and less than one hundred and thirty degrees. An air permeability of the core wrap is no less than one thousand, three hundred and fifty cubic meters per hour and no KCX-2165- PCT / 65131214PCT02 greater than one thousand, five hundred cubic meters per hour. A basis weight of the top sheet layer is no less than fifteen grams per square meter and no greater than twenty-five grams per square meter, and a basis weight of the core wrap is no less than eighteen grams per square meter and no greater than forty-five grams per square meter.

[0015] 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.

[0016] BRIEF DESCRIPTION OF THE DRAWINGS

[0017] 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.

[0018] FIG. 1 is a top plan view of an absorbent article according to example aspects of the present disclosure.

[0019] FIG. 2 is a schematic, section view of the example absorbent article of FIG. 1 .

[0020] FIG. 3 is a schematic, section view of an absorbent core of the example absorbent article of FIG. 1 .

[0021] FIG. 4 is a schematic view of a process for forming core assemblies according to example aspects of the present disclosure.

[0022] FIGS. 5 though 7 are tables of experimental data.

[0023] 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 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.

[0026] 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. KCX-2165- PCT / 65131214PCT02

[0027] 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.

[0028] 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.

[0029] 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

[0030] Definitions:

[0031] 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.

[0032] 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.

[0033] 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 KCX-2165- PCT / 65131214PCT02 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.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] 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 KCX-2165- PCT / 65131214PCT02 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.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] 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 KCX-2165- PCT / 65131214PCT02 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.

[0045] The term “gsm” refers herein to grams per square meter.

[0046] The term “layer” when used in the singular can have the dual meaning of a single element or a plurality of elements.

[0047] 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.

[0048] The term “liquid permeable” refers herein to any material that is not liquid impermeable.

[0049] 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.

[0050] The term “member" when used in the singular can have the dual meaning of a single element or a plurality of elements.

[0051] 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.

[0052] 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 pm), to about twenty microns (20 pm). KCX-2165- PCT / 65131214PCT02

[0053] 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.

[0054] 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.

[0055] 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 850pm.

[0056] 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.

[0057] 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.

[0058] 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 KCX-2165-PCT / 65131214PCT02

[0059] (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. These terms may be defined with additional language in the remaining portions of the specification.

[0060] KCX-2165- PCT / 65131214PCT02

[0061] Absorbent Article

[0062] FIG. 1 is a top plan view of an absorbent article 100 according to example embodiments of the present subject matter. FIG. 2 is a section view of the example absorbent article 100. The absorbent article 100 may be a feminine care article, such as an absorbent feminine care pantiliner, pad, or napkin. The absorbent article 100 may define a lengthwise longitudinal direction 102 and a transverse, laterally extending cross-direction 104. The absorbent article 100 may extend between first and second longitudinally opposed end portions 105, 106 along the longitudinal direction 102, and an intermediate portion 107 of the absorbent article 100 may be disposed between the first and second end portions 105, 106 along the longitudinal direction 102. As representatively shown, the longitudinal dimension of the absorbent article 100 may be relatively larger than the lateral dimension of the article. Thus, the absorbent article 100 may be elongated along the longitudinal direction 102 relative to the cross-direction 104.

[0063] The absorbent article 100 may include a cover or top sheet 110, a baffle or back sheet 120, and an absorbent core 130. The absorbent core 130 is positioned between the top sheet 110 and the back sheet 120. The top sheet 110 and the absorbent core 130 may be configured with absorbent capacities, densities, basis weights, and / or sizes that provide advantageous combinations of liquid intake time, absorbent retention capacity, rewet performance, shape maintenance, and / or aesthetics.

[0064] As described in greater detail below, by incorporating various features, aspects, and configurations, alone or in desired combinations, the absorbent article 100 can provide an improved absorbent system that can take better advantage of the functional properties of the top sheet 110 and the absorbent core 130. For example, the absorbent article 100 can provide comparable or improved absorbent capacity when compared to conventional absorbent articles. Similarly, the absorbent article 100 can provide comparable or improved absorbent capacity while reducing thickness, as well as improved production costs, when compared to conventional absorbent articles. The absorbent article 100 can also provide improved appearance and aesthetics. As a result, the absorbent article 100 can provide greater comfort and fit, and can improve protection and increase confidence.

[0065] The top sheet 110 may be configured to be operatively liquid-permeable to allow body exudates to pass through the top sheet 110 to the underlying absorbent core 130 within the absorbent article 100. Thus, e.g., the top sheet 110 may include a layer constructed of operative material, such as a nonwoven fabric. Example nonwoven fabrics of the top sheet 110 include spunbond fabric, meltblown fabric, coform fabric, carded web, bonded carded web, bicomponent spunbond fabric, or the like as well as combinations thereof. Certain example suitable materials for constructing the top sheet 110 include rayon, bonded carded webs of polyester, polypropylene, polyethylene, nylon, or other KCX-2165- PCT / 65131214PCT02 heat-bondable fibers, polyolefins, such as copolymers of polypropylene and polyethylene, linear low- density polyethylene, biodegradable aliphatic polyesters such as poly(hydroxyl alkanoates) and polyactic acid, and the like, as well as combinations thereof. A particular example of a suitable material for the top sheet 110 can include a bonded-carded-web of polypropylene and polyethylene, such as has been used as a cover stock for KOTEX brand pantiliners, and has been obtainable from Vliesstoffwerk Christian Heinrich Sandler GmbH & Co. KG, a business having an address at Postfach 1144, D95120 Schwarzenbach / Saale, Germany. Other examples of suitable materials are composite materials of a polymer and a nonwoven fabric material. The composite materials are typically in the form of integral sheets generally formed by the extrusion of a polymer onto a web of spunbond material. In example embodiments, a basis weight of the top sheet 110 may be no less than fifteen grams per square meter (15 gsm) and no greater than twenty-five grams per square meter (25 gsm). In example embodiments, a first strikethrough of the top sheet 110 may be no less than one and two- tenths seconds (1 .2 s) and no greater than three and five-tenths seconds (3.5 s).

[0066] As noted above, the top sheet 110 may be configured to be operatively liquid-permeable with regard to the liquids that the absorbent article 100 is intended to absorb or otherwise handle. The operative liquid-permeability may, for example, be provided by a plurality of pores, perforations, apertures or other openings, as well as combinations thereof, that are present or formed in the top sheet 110. The apertures or other openings can help increase the rate at which bodily liquids can move through the thickness of the top sheet 110 and penetrate into the other components of the article (e.g., the absorbent core 130). The selected arrangement of liquid-permeability is suitably present at least on an operative portion of the top sheet 110 that is appointed for placement on the body-side of the article. The top sheet 110 can provide comfort and conformability, and can function to direct viscous fluids, such as menses, away from the body and toward the absorbent core 130. In one example, the top sheet 110 can be configured to retain little or no liquid within the structure of the top sheet 110, and can be configured to provide a relatively comfortable and non-irritating surface next to the body-tissues of a wearer. The top sheet 110 can be constructed of any material which is also easily penetrated by viscous fluids that contact the surface of the top sheet 110.

[0067] The top sheet 110 may have at least a portion of a bodyside surface of the top sheet 110 treated with a surfactant to render the top sheet 110 more hydrophilic. The surfactant can permit arriving viscous liquids to more readily penetrate the top sheet 110. The surfactant may also diminish the likelihood that the arriving viscous fluids, such as menses, will flow off the top sheet 110 rather than penetrate through the top sheet 110 into other components of the article. In example embodiments, the surfactant can be substantially evenly distributed across at least a portion of the KCX-2165- PCT / 65131214PCT02 upper, bodyside surface of the top sheet 110 that overlays a body-facing surface 132 of the absorbent core 130.

[0068] The top sheet 110 may be maintained in secured relation with the absorbent core 130 by bonding all or a portion of the adjacent surfaces to one another. A variety of bonding techniques known to one of skill in the art may be utilized to achieve any such secured relation. Examples of such techniques include, but are not limited to, the application of adhesives in a variety of patterns between the two adjoining surfaces, entangling at least portions of the adjacent surface of the absorbent core 130 with portions of the adjacent surface of the top sheet 110, co-aperturing or fusing at least portions of the adjacent surface of the top sheet 110 to portions of the adjacent surface of the absorbent core 130, and the like.

[0069] The top sheet 110 typically extends over the body-facing surface 132 of the absorbent core 30. In certain example embodiments, the top sheet 110 may extend around the absorbent article 100 to partially, or entirely, surround or enclose the absorbent core 130. In other example embodiments, the top sheet 110 and the back sheet 120 may have peripheral margins that extend outwardly beyond the terminal, peripheral edges of the absorbent core 130, and the extending margins can be joined together to partially, or entirely, surround or enclose the absorbent core 130.

[0070] The back sheet 120 may include a layer constructed of an operative material, and the back sheet 120 may or may not have a selected level of liquid-permeability or liquid-impermeability, as desired. In example embodiments, the back sheet 120 may be configured to provide an operatively liquid-impermeable baffle structure. The back sheet 120 may, for example, include a polymeric film, a woven fabric, a nonwoven fabric or the like, as well as combinations or composites thereof. For example, the back sheet 120 may include a polymer film laminated to a woven or nonwoven fabric. In a particular feature, the polymer film can be composed of polyethylene, polypropylene, polyester or the like, as well as combinations thereof. Additionally, the polymer film may be micro-embossed, have a printed design, have a printed message to the consumer, and / or may be at least partially colored. Suitably, the back sheet 120 can operatively permit a sufficient passage of air and moisture vapor out of the absorbent article 100, particularly out of the absorbent core 130, while blocking the passage of bodily liquids. An example of a suitable material for the back sheet 120 may include a breathable, microporous film, such as a HANJIN Breathable Baffle available from Hanjin Printing, Hanjin P&C Company Limited, a business having offices located in Sahvon-li.Jungan-mvu.Kongiu-City, Chung cheong nam-do, Republic of South Korea. This baffle material is a breathable film, which is white in color, dimple embossed, and contains: 47.78% calcium carbonate, 2.22% TIO2, and 50% polyethylene. KCX-2165- PCT / 65131214PCT02

[0071] In example embodiments, the polymer film of the back sheet 120 may have a minimum thickness of no less than about 0.025 mm and / or may have a maximum thickness of no greater than about 0.13 mm. Bicomponent films or other multi-component films can also be used, as well as woven and / or nonwoven fabrics which have been treated to render them operatively liquid-impermeable. Another suitable baffle material can include a closed-cell polyolefin foam. For example, a closed-cell polyethylene foam may be employed. Still another example of a baffle material would be a material that is similar to a polyethylene film which is used on commercially sold KOTEX brand pantiliners, and is obtainable from Pliant Corporation, a business having offices located in Schaumburg, III., USA.

[0072] As shown in FIG. 2, the absorbent core 130 may be disposed between the front sheet 110 and the back sheet 120. As noted above, the front sheet 110 may be liquid permeable and may perform well in the uptake and wicking of fluid. Conversely, the back sheet 120 may be liquid impermeable and may limit or prevent fluid transmission therethrough. The absorbent core 130 may extend between a bodyside facing portion 132 and an outwardly facing portion 134, e.g., along a transverse direction 108, which may be mutually perpendicular to the longitudinal direction 102 and the cross-direction 104. The bodyside facing portion 132 of the absorbent core 130 may be positioned at and / or face towards the front sheet 110. The outwardly facing portion 134 of the absorbent core 130 may be positioned at and / or face towards the back sheet 120.

[0073] As may be seen in FIG. 2, the absorbent core 130 may be positioned on and contact the front sheet 110. For instance, the bodyside facing portion 132 of the absorbent core 130 may directly contact the front sheet 110. Thus, e.g., the absorbent article 100 may not include a surge or acquisition / distribution layer between the bodyside facing portion 132 of the absorbent core 130 and the front sheet 110. Moreover, the absorbent article 100 may not include a surge or acquisition / distribution layer between a nonwoven core wrap 160 (FIG. 3) of the absorbent core 130 and the front sheet 110. Conventional absorbent articles include surge or acquisition / distribution layers between the absorbent core and the front sheet in order to facilitate fluid flow from the bodyside liner and the absorbent body and thereby speeding up fluid intake times. The absorbent core 130 can surprisingly provide comparable or improved fluid intake times despite the lack of a surge or acquisition / distribution layer. Omission of a surge or acquisition / distribution layers can also advantageously reduce a thickness of the absorbent article 100 relative to conventional absorbent articles with surge or acquisition / distribution layers, which can make the absorbent article 100 more comfortable to wear. Conventional surge or acquisition / distribution layers can 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 KCX-2165- PCT / 65131214PCT02 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).

[0074] The absorbent core 130 may include a composite structure as discussed in greater detail below in the context of FIGS. 2 and 3 The absorbent core 130 may be sized and placed to more effectively operate in a target area of the absorbent article 100 where liquids are more likely to be introduced into the absorbent article 100. The structure of the absorbent core 130 may be operatively configured to provide a desired level of absorbency or storage capacity. In example embodiments, a total absorbent capacity of the absorbent article 100 is no less than one hundred grams (100 g) and / or no greater than three hundred grams (300 g). In example embodiments, a ratio of the total absorbent capacity to a dry weight of the absorbent article 100 may be from 15:1 to 19:1. In example embodiments, a pressurized rewet of the absorbent article 100 may be no less than five-hundredths gram (0.05 g) and no greater than seventeen-hundredths gram (0.17 g). In example embodiments, an intake time of the absorbent article 100 may be no less than four seconds (4 s) and no greater than six seconds (6 s).

[0075] Absorbent Core

[0076] FIG. 3 is a section view of the absorbent core 130. The absorbent core 130 includes absorbent material. 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 core 130, 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.

[0077] As shown in FIG. 3, the absorbent core 130 may include a superabsorbent layer 140 and an airlaid layer 150. The superabsorbent layer 140 and the airlaid layer 150 may be discrete and separate from each other within the absorbent core 130. Thus, the absorbent core 130 may include two (2) or more layers of absorbent material with different absorbent material compositions. In example embodiments, the superabsorbent layer 140 may be positioned at or adjacent the bodyside facing portion 132 of the absorbent core 130, and the airlaid layer 150 may be positioned at or adjacent the outwardly facing portion 134 of the absorbent core 130.

[0078] The superabsorbent layer 140 may include superabsorbent particles. In example embodiments, the superabsorbent particles may be present within the superabsorbent layer 140 at no less than ninety percent (90%), such as no less than ninety-five percent (95%), no less than ninetyseven percent (97%), by weight of the superabsorbent layer 140. The superabsorbent layer 140 may KCX-2165- PCT / 65131214PCT02 also include an adhesive for bonding the superabsorbent particles together within the superabsorbent layer 140. In example embodiments, the adhesive may be present within the superabsorbent layer 140 at no greater than ten percent (10%), such as no greater than five percent (5%), such as no greater than three percent (3%), by weight of the superabsorbent layer 140. The adhesive may be applied by spraying directly on the superabsorbent particles or spraying on a nonwoven core wrap 160.

[0079] As may be seen from the above, the superabsorbent layer 140 may be predominantly composed of superabsorbent particles. Moreover, the superabsorbent layer 140 may be essentially free of cellulosic fluff fibers and / or be fluff-free. A basis weight of the superabsorbent layer 140 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 140 may be constructed by patterning the superabsorbent particles for smooth distribution of the fluid.

[0080] The airlaid layer 150 may include cellulosic fluff fibers and synthetic binder fibers. The cellulosic fluff fibers may be present within the airlaid layer 150 at no less than fifty percent (50%) and no greater than ninety percent (90%), such as no less than seventy percent (70%) and no greater than eighty-five percent (85%), such as about eighty percent (40%), by weight of the airlaid layer 150. In example embodiments, the synthetic binder fibers may be present within the airlaid layer 150 at no less than ten (10%) and no greater than fifty percent (50%), such as no less than fifteen percent (15%) and no greater than thirty percent (30%), such as about twenty percent (20%), by weight of the airlaid layer 150. The synthetic binder fibers may provide stabilization and attachment for the airlaid layer 150 when appropriately activated.

[0081] A basis weight of the airlaid layer 150 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 airlaid layer 150 may be essentially free of cross-linked cellulose fibers, including crimped, twisted, or curled crosslinked cellulose fibers. In example embodiments, the superabsorbent particles in the superabsorbent layer 140 may be a common type and / or grade as the superabsorbent particles in the airlaid layer 150.

[0082] The example absorbent core 130 in FIG. 3 may also include a nonwoven core wrap 160. The nonwoven core wrap 160 may be disposed on and / or contact the superabsorbent layer 140 and the airlaid layer 150. For instance, the nonwoven core wrap 160 may be wrapped or otherwise disposed around the superabsorbent layer 140 and the airlaid layer 150. Moreover, the nonwoven core wrap 160 may surround the superabsorbent layer 140 and the airlaid layer 150, e.g., in a plane that is KCX-2165- PCT / 65131214PCT02 perpendicular to the longitudinal direction 102. The nonwoven core wrap 160 may assist with limiting or preventing escape of absorbent material from the absorbent core 130.

[0083] In example embodiments, the nonwoven core wrap 160 may be folded around the superabsorbent layer 140 and the airlaid layer 150 in a “D-wrap.” Thus, opposite ends of the nonwoven core wrap 160 may overlap in order to surround the superabsorbent layer 140 and the airlaid layer 150. The seam of the "D-wrap” nonwoven core wrap 160 may be positioned at or adjacent the outwardly facing portion 132 of the absorbent core 130 as shown in FIG. 2. In other example embodiments, the seam of the “D-wrap" nonwoven core wrap 160 may be positioned at or adjacent the bodyside facing portion 132 of the absorbent core 130. Thus, e.g., the seam of the nonwoven core wrap 160 may be positioned at or adjacent the same portion of the absorbent core 130 in example embodiments. Other formations of the nonwoven core wrap 160 are also within the scope of the present disclosure, such as “C-wraps.”

[0084] The nonwoven core 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 core wrap 160 may have a basis weight of between about eighteen grams per square meter (18 gsm) and about foryt-five grams per square meter (45 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. In example embodiments, an air permeability of the nonwoven core wrap 160 may be no less than one thousand, three hundred and fifty cubic meters per hour (1350 m3 / h) and no greater than one thousand, five hundred cubic meters per hour (1500 m3 / h). Such properties can configure the nonwoven core wrap 160 to facilitate fluid flow from the top sheet 110 to the absorbent core 130 and thereby speed up fluid intake times.

[0085] Additionally, in order to maintain the absorbent core 130 as a cohesive structure and to assist in stabilizing the absorbent material within the absorbent core 130, the absorbent core 130 may include additional adhesives. In general, adhesive may be applied to different materials of the absorbent core 130 so as to form different adhesive layers. For example, some embodiments may include an adhesive layer between the nonwoven core wrap 160 and the superabsorbent layer 140, e.g., applied to one or both of the nonwoven wrap 160 and the superabsorbent layer 140.

[0086] The absorbent cores 130 of the present disclosure may include absorbent material and nonwoven wraps to provide the absorbent cores 130 with beneficial fluid intake and storage (e.g. fluid retention) qualities. KCX-2165- PCT / 65131214PCT02

[0087] Formation Process:

[0088] FIG. 4 is an exemplary schematic depiction of an absorbent structure formation process 300. Process 300 may be used to form absorbent cores, such as the absorbent core 130. As shown in FIG. 4, 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.

[0089] 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.

[0090] 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.

[0091] 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 KCX-2165- PCT / 65131214PCT02 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.

[0092] 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 324 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 324 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.

[0093] 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.

[0094] 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. KCX-2165- PCT / 65131214PCT02

[0095] 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.

[0096] 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.

[0097] 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.

[0098] 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 .

[0099] 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.

[0100] The absorbent assembly may pass through a folder 350 to fold the first web material 310 around the other portions of the absorbent assembly. The absorbent assembly 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 KCX-2165- PCT / 65131214PCT02 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.

[0101] After the one or more nip stations 360, the combination of the absorbent assembly 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.

[0102] In alternative example embodiments, the method of manufacture 300 may not include the material deposition station 320. Rather, an airformed fibrous web may be formed off-line and brought into process 300 on a supply roll. In such example embodiments, the airformed fibrous web may be unwound and applied to the deposited mixture 346 when the deposited mixture 346 is present on the second web material 312 and before the third web material 314 is applied to the deposited mixture 346. In such example embodiments, first web 310 may be absent, and the second web 312 may be folded around the deposited mixture 346 and the airformed fibrous web to form the corewrap. In these example embodiments, the airformed fibrous web may be formed of pulp fluff and synthetic fibers, such as polypropylene or other polyolefin fibers.

[0103] In still other alternative example embodiments where the material deposition station 320 is absent, the third web material 314 may be the airformed fibrous web that is applied directly to the deposited mixture 346. The second web material 312 then may include the corewrap material of the absorbent core 130 which is folded around the deposited mixture 346 and the third web material 314 (e.g. the airformed web material) to form the enclosed absorbent core 130. In such instances, the absorbent core 130 would not include a separate, third web material different from the airformed fibrous web within the absorbent core 130 which would only be formed of the second web material 312 as the corewrap, the deposited mixture 346, and the airformed web material (the third web material 314 in this example embodiment).

[0104] FIG. 4 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. KCX-2165- PCT / 65131214PCT02

[0105] Test Methods:

[0106] Absorption Capacity Test

[0107] The absorption capacity of experimental codes was measured according to the following protocol. First, 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 absorption capacity test was performed using a table top absorption 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 absorption capacity is the total weight of the wet sample minus the sample dry weight.

[0108] FIUP Test

[0109] The first, second, and third intake times of experimental codes were measured according to the following protocol for a Fluid Intake Under Pressure (FIUP) Test. The samples were first brought to TAPPI conditions for at least 4 hours.

[0110] The FIUP Test uses a “bladder box" with a cover, a housing, an inflatable bladder, and a control unit. The cover can be made from a clear material, such as clear, cast acrylic. The cover can be hinged to the housing. The housing can be constructed from aluminum can be of the size of 62cm x 40cm x 15cm. The housing can also include latches for securing the cover to the housing. When the cover is opened, the test specimen can be laid on top of a thin plastic film that is laid on top of the bladder. The test specimen should be laid on the film and bladder such that the specimen is centered under the intake port. The bladder can be an inflatable bladder, such as an Aero Tec Labs bladder, that can fit within the housing and that can be filled with compressed air.

[0111] The intake port can include a threaded funnel that threads into a threaded plug having a 1” diameter opening at the bottom of the threaded plug and provides for communication to the test KCX-2165- PCT / 65131214PCT02 specimen. The intake port can also include an O-ring that seals the threaded plug with the cover. The intake port can also include a round, flat gasket (not shown) to seal between the threaded funnel and the threaded plug. The bottom of the intake port should be flush with the underside of the cover.

[0112] The control unit can be a process controller such as 1 / 16 DIN Fuzzy Logic; Example: Omega, part number CN48001 -F1 -AL2:G1 , or equivalent, and can be configured to be in communication with a pressure transmitter measuring the pressure of the bladder. An exemplary pressure transmitter can be an Omega Engineering, part number PX181-015GSV. The control unit can also be in communication with a fluid dispensing pump (e.g ., Cole-Parmer peristaltic pump, P / N 07551-20) and pump head (P / N 77201-60) that is set up to deliver fluid to the test sample at a specified flow rate of 8mL / s via clear pump tubing (e.g., Masterflex clear tubing L / S 14, L / S 25, or L / S 17). The end fitting on the tubing can have an exit diameter of 0.125”, such as Cole-parmer Reducing Connector, Nylon, 1 / 4" x 3 / 16”, Item No. 30622-30.

[0113] After the test specimen is set in the bladder box housing by being centered below the intake port. The bottom of the cover can include two strips of hook tape (e.g., Item # 1055, Dariss Brand) that are used to help secure the test specimen. After the sample is centered, the cover is closed and latches are latched. The hook tape should be applied to the cover such that the hook tape only touches non-absorbent material of the test specimen. The power for the control unit is turned on to set the bladder pressure to 0.25psi. Once the control unit 204 identifies that the bladder has reached a stable pressure of 0.25psi, a pressure gauge can be checked to verify that the pressure in the bladder is within 0.25 + / - 0.01 psi. If the pressure is not within 0.01 psi of 0.25psi, the test should be stopped and the set pressure should be adjusted to compensate until the pressure gauge reads within 0.01 psi of 25psi.

[0114] The insult liquid used for the FIUP test is 0.9 ± 0.005% (w / w) aqueous isotonic saline that is placed in a heated water bath at a temperature of 98.6 ± 1 .8 °F / 37 ± 1 °C prior to testing. The saline solution temperature should be confirmed with a thermometer prior to insulting the test specimen. The first insult is a 25mL insult and is supplied through the intake port by aiming the fluid at the bottom angled side of the funnel The first intake time of the first insult begins once the pump is turned on to deliver fluid to the intake port and continues until all droplets of fluid have been absorbed within top layer of the test specimen. The second 25mL insult is applied 15 minutes after the first insult is fully absorbed and the second intake time is measured in the same manner as the first insult time. The third 25mL insult is applied 15 minutes after the second insult is fully absorbed and the third intake time is measured in the same manner as described above. KCX-2165- PCT / 65131214PCT02

[0115] After the third intake time is recorded, a timer should be started to allow two minutes to pass. The control unit is then calibrated to stop the test by releasing the bladder pressure in the bladder box.

[0116] If any point during the insult testing there is any fluid runoff beyond the test specimen on to the plastic sheet covering the bladder, the test should be marked as a "FAIL” and not recorded.

[0117] The testing is conducted with a sample set of N=5.

[0118] Rewet Test

[0119] The rewet for the experimental codes was measured by using the same specimen from the FIUP test discussed above. The rewet test is a continued test after the FIUP test was completed. Specifically, 2 minutes after the third insult of the FIUP test is complete, the sample is removed from the bladder box and placed onto a flat surface, insult side facing up. The test is completed using two stacked pieces of blotting paper (e.g., 300 g / m2 (100 Ib. / ream) - Verigood Grade 88 by 300 ± 13 mm (3.5 by 12 ± 0.5 inch)) to absorb the free saline from the insulting point of the specimen under an external load after the FIUP test. The two pieces of blotting paper were pre-weighed and each had a dimension of 3.5” x 12” and would be placed to cover the center of the specimen's insulting point by removing the FIUP testing board and adding a cylindrical weight of 1096 g and having a 2.4 inch diameter on the top of the blotting papers at the insult point to create a pressure of 0.5 psi for a period of two minutes. The mass of the wetted blotter papers is then measured and the rewet is calculated as: Rewet = total wet mass - dry mass. The higher the amount of wet weight measured from the test, the higher the rewet value the specimen had.

[0120] Thickness Measurements

[0121] Both dry thickness and wet thickness measurements of experimental codes were measured as part of the FIUP test discussed above. The thickness measurements utilize a standard bulk tester with clear, cast acrylic foot that provides 0.05psi. The dry thickness measures the dry bulk at the center point when the sample is dry and measures the thickness of the sample in a full product form. The wet thickness is measured after the rewet testing is complete by measuring the bulk at the center point.

[0122] Horizontal Side Compression Test

[0123] The Horizontal Side Compression Test compresses the sample horizontally. The Test protocol has 10 cycles of dry testing. Test outputs used in this description include cycle 1 energy (g*cm) and cycle 10 recovery (%).

[0124] To perform the Horizontal Side Compression Test, a Constant Rate of Elongation (CRE) type of tensile tester with data acquisition unit and data acquisition program capable of collecting data such as Instron 3343 system with Bluehill program or MTS Insight 1 EL system with TestWorks 4.0 is used. KCX-2165- PCT / 65131214PCT02

[0125] The Test is conducted by warming up the tensile tester according to the manufacturer's manual. Next, verify the appropriate load cell is in the tensile tester, which should be selected from either a 50 Newton or 100 Newton maximum, depending on the peak force value of the sample being tested, such that the majority of peak load values fall between 5-95% of the load cell's full scale value. For purposes of the samples tested herein, a 100 Newton load cell was used. In this test, both edges of the sample are clamped between top and bottom grips of the tensile tester with the center of the sample aligned with the center of the grips and the sample centered between the grips. Turn on the computer and follow the software menu selection. Follow the manufacturer’s instructions for calibrating the load cell for the tensile tester. Verify the test conditions are as documented in the table below.

[0126] Ensure the lanyard thread is in and remains in the whee guides, one in the front and two wheel guides in the back of the tester . A piece of masking tape can be placed close to one of the back wheels of the tester without touching the lanyard to prevent the lanyard moving out of the wheel when the crosshead returns to its start position. Two hanging weights are attached to the wheel guide at the far back of the testing unit. Orient the weights up-side down to shorten the hook length such that the weights do not touch the frame.

[0127] With the lanyard attached to a hook below the load cell, adjust the crosshead so the resultant force exerted by the lanyard is less than 0.5 grams. Measure and then record the initial width of the specimen in the mid-crotch area. Then, zero the crosshead channel and start the test run. At the conclusion of the 10 cycles, measure and record the final width of the specimen in the mid-crotch area. A data report is generated that provides the cycle 1 energy (g*cm). The cycle 10 recovery % is measured as final width at cycle 10 divided by the initial width, multiplied by 100.

[0128] Examples:

[0129] Performance of sample inventive absorbent articles (Samples #1 , #2, #3) was evaluated relative to comparative absorbent articles with surge layers (Samples #4, #5, #6) as well as comparative conventional absorbent articles (Samples #7, #8). For each sample, three sizes were evaluated, namely 3-drop, 4-drop, and 5-drop sizes.

[0130] The absorbent cores of the inventive Samples #1 , #2, #3 and the comparative Samples #4, KCX-2165- PCT / 65131214PCT02

[0131] #5, #6 had the following specification for each drop size:

[0132] The airlaid layer contains 80% fluff and 20% synthetic binder fiber. The superabsorbent layer contains 5% adhesive. Samples #1 , #2, #3 and comparative Samples #4, #5, #6 had a spunbond 20 gsm top cover. Samples #1 , #2, #3 had no surge layer, and Samples #4, #5, #6 had a bonded carded web 42 gsm surge layer. The comparative Sample #4 was a Poise® Ultra Thin incontinence pad, and the comparative Sample #5 was an Always® Discreet incontinence pad.

[0133] Various sample properties of Samples #1 through #8 are shown in the table in FIG. 5, FIG. 6, and FIG. 7. The results for the 3-drop size of Samples #1 through #8 is shown in FIG. 5. The results for the 4-drop size of Samples #1 through #8 is shown in FIG. 6. The results for the 5-drop size of Samples #1 through #8 is shown in FIG. 7.

[0134] As may be seen the tables in FIGS. 5 through 7, the inventive samples advantageously provide a thinner absorbent structure than all but one comparative sample (Sample #7), which is significantly smaller by mass. The inventive samples can also have enough void volume and absorbency under load to manage the liquid insults, while also maintaining low levels of rewet. Surprisingly, elimination of surge layer consistently reduced the levels of rewet in inventive samples. Moreover, decreasing the basis weight of the core wrap resulted in reduced rewet values.

[0135] 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.

[0136] KCX-2165- PCT / 65131214PCT02

[0137] EXAMPLE EMBODIMENTS

[0138] First example embodiment: An absorbent article, comprising: a top sheet; a back sheet; an absorbent core disposed between the top sheet and the back sheet, the absorbent core comprising a superabsorbent layer with superabsorbent particles bonded together with an adhesive; and a core wrap disposed around the absorbent core, the core wrap contacting the top sheet, wherein a thickness of the absorbent article between the top sheet and the back sheet at the absorbent core is no less than two millimeters and no greater than four millimeters, wherein a total absorbent capacity of the absorbent article is no less than one hundred grams, and wherein a pressurized rewet of the absorbent article is no less than five-hundredths gram and no greater than seventeen-hundredths gram.

[0139] Second example embodiment: The absorbent article of the first example embodiment, wherein a basis weight of the top sheet is no less than fifteen grams per square meter and no greater than twenty-five grams per square meter.

[0140] Third example embodiment: The absorbent article of either the first example embodiment or the second example embodiment, wherein the top sheet comprises a spunbond web, and the core wrap comprises a through-air bonded carded web.

[0141] Fourth example embodiment: The absorbent article of any one of the first through third example embodiments, wherein the superabsorbent particles are present within the superabsorbent layer at no less than ninety percent by weight of the superabsorbent layer.

[0142] Fifth example embodiment: The absorbent article of any one of the first through fourth example embodiments, wherein a top surface of the core wrap faces towards and is positioned in direct contact with an inner surface of the top sheet.

[0143] Sixth example embodiment: The absorbent article of any one of the first through fifth example embodiments, wherein a surge layer is not disposed between the core wrap and the top sheet.

[0144] Seventh example embodiment: The absorbent article of any one of the first through sixth example embodiments, wherein a basis weight of the core wrap is no less than eighteen grams per square meter and no greater than forty-five grams per square meter.

[0145] Eighth example embodiment: The absorbent article of any one of the first through seventh example embodiments, wherein an air permeability of the core wrap is no less than one thousand, three hundred and fifty cubic meters per hour and no greater than one thousand, five hundred cubic meters per hour. KCX-2165-PCT / 65131214PCT02

[0146] Nineth example embodiment: The absorbent article of any one of the first through eighth example embodiments, wherein a first strikethrough of the top sheet is no less than one and two- tenths seconds and no greater than three and five-tenths seconds.

[0147] Tenth example embodiment: The absorbent article of any one of the first through nineth example embodiments, wherein the absorbent core further comprises an airlaid layer with cellulosic fluff bound together with synthetic binder fibers, the airlaid layer disposed on the superabsorbent layer within the core wrap.

[0148] Eleventh example embodiment: The absorbent article of any one of the first through tenth example embodiments, wherein the cellulosic fluff is present within the airlaid layer at no less than seventy percent by weight of the airlaid layer, and the synthetic binder fibers are present within the airlaid layer at no less than ten percent by weight of the airlaid layer. Twelfth example embodiment: The absorbent article of any one of the first through eleventh example embodiments, wherein the total absorbent capacity of the absorbent article is no greater than three hundred grams.

[0149] Thirteenth example embodiment: The absorbent article of any one of the first through twelfth example embodiments, wherein an intake time of the absorbent article is no less than four seconds and no greater than six seconds.

[0150] Fourteenth example embodiment: The absorbent article of any one of the first through thirteenth example embodiments, wherein a ratio of the total absorbent capacity to a dry weight of the absorbent article is from 15:1 to 19:1.

[0151] Fifteenth example embodiment: An absorbent article, comprising: a top sheet; a back sheet; an absorbent core disposed between the top sheet and the back sheet, the absorbent core comprising a superabsorbent layer with superabsorbent particles present within the superabsorbent layer at no less than ninety percent by weight of the superabsorbent layer; and a core wrap disposed around the absorbent core, the core wrap contacting the top sheet layer, wherein an intake time of the absorbent article is no less than four seconds and no greater than six seconds, wherein a water contact angle to the top sheet layer is greater than ninety degrees and less than one hundred and thirty degrees, wherein an air permeability of the core wrap is no less than one thousand, three hundred and fifty cubic meters per hour and no greater than one thousand, five hundred cubic meters per hour, and wherein a basis weight of the top sheet layer is no less than fifteen grams per square meter and no greater than twenty-five grams per square meter, and a basis weight of the core wrap is no less than eighteen grams per square meter and no greater than forty-five grams per square meter. KCX-2165-PCT / 65131214PCT02

[0152] Sixteenth example embodiment: The absorbent article of the fifteenth example embodiment, wherein a thickness of the absorbent article between the top sheet and the back sheet at the absorbent core is no less than two millimeters and no greater than four millimeters.

[0153] Seventeenth example embodiment: The absorbent article of either of the fifteenth or sixteenth example embodiments, wherein a total absorbent capacity of the absorbent article is no less than one hundred grams and no greater than three hundred grams.

[0154] Eighteenth example embodiment: The absorbent article of any one of the fifteenth through seventeenth example embodiments, wherein a pressurized rewet of the absorbent article is no less than five-hundredths gram and no greater than seventeen-hundredths gram.

[0155] Nineteenth example embodiment: The absorbent article of any one of the fifteenth through eighteenth example embodiments, wherein the superabsorbent particles are present within the superabsorbent layer at no less than ninety percent by weight of the superabsorbent layer.

[0156] Twentieth example embodiment: The absorbent article of any one of the fifteenth through nineteenth example embodiments, wherein a top surface of the core wrap faces towards and is positioned in direct contact with an inner surface of the top sheet.

[0157] Twenty-First example embodiment: The absorbent article of any one of the fifteenth through twentieth example embodiments, wherein a surge layer is not disposed between the core wrap and the top sheet.

[0158] Twenty-Second example embodiment: The absorbent article of any one of the fifteenth through twenty-first example embodiments, wherein a first strikethrough of the top sheet is no less than one and two-tenths seconds and no greater than three and five-tenths seconds.

[0159] Twenty-Third example embodiment: The absorbent article of any one of the fifteenth through twenty-second example embodiments, wherein the absorbent core further comprises an airlaid layer with cellulosic fluff bound together with synthetic binder fibers, the airlaid layer disposed on the superabsorbent layer within the core wrap.

[0160] Twenty-Fourth example embodiment: The absorbent article of any one of the fifteenth through twenty-third example embodiments, wherein the cellulosic fluff is present within the airlaid layer at no less than seventy percent by weight of the airlaid layer, and the synthetic binder fibers are present within the airlaid layer at no less than ten percent by weight of the airlaid layer.

[0161] Twenty-Fifth example embodiment: The absorbent article of any one of the fifteenth through twenty-fourth example embodiments, wherein a ratio of the total absorbent capacity to a dry weight of the absorbent article is from 15:1 to 19:1.

Claims

KCX-2165-PCT / 65131214PCT02What Is Claimed:1 . An absorbent article, comprising: a top sheet; a back sheet; an absorbent core disposed between the top sheet and the back sheet, the absorbent core comprising a superabsorbent layer with superabsorbent particles bonded together with an adhesive; and a core wrap disposed around the absorbent core, the core wrap contacting the top sheet, wherein a thickness of the absorbent article between the top sheet and the back sheet at the absorbent core is no less than two millimeters and no greater than four millimeters, wherein a total absorbent capacity of the absorbent article is no less than one hundred grams, and wherein a pressurized rewet of the absorbent article is no less than five-hundredths gram and no greater than seven teen-hundred ths gram.

2. The absorbent article of claim 1 , wherein a basis weight of the top sheet is no less than fifteen grams per square meter and no greater than twenty-five grams per square meter.

3. The absorbent article of claim 1 , wherein the top sheet comprises a spunbond web, and the core wrap comprises a through-air bonded carded web.

4. The absorbent article of claim 1 , wherein the superabsorbent particles are present within the superabsorbent layer at no less than ninety percent by weight of the superabsorbent layer.

5. The absorbent article of claim 1 , wherein a top surface of the core wrap faces towards and is positioned in direct contact with an inner surface of the top sheet.

6. The absorbent article of claim 5, wherein a surge layer is not disposed between the core wrap and the top sheet.

7. The absorbent article of claim 1 , wherein a basis weight of the core wrap is no less than eighteen grams per square meter and no greater than forty-five grams per square meter.KCX-2165-PCT / 65131214PCT028. The absorbent article of claim 1 , wherein an air permeability of the core wrap is no less than one thousand, three hundred and fifty cubic meters per hour and no greater than one thousand, five hundred cubic meters per hour.

9. The absorbent article of claim 1 , wherein a first strikethrough of the top sheet is no less than one and two-tenths seconds and no greater than three and five-tenths seconds.

10. The absorbent article of claim 1 , wherein the absorbent core further comprises an airlaid layer with cellulosic fluff bound together with synthetic binder fibers, the airlaid layer disposed on the superabsorbent layer within the core wrap.11 . The absorbent article of claim 10, wherein the cellulosic fluff is present within the airlaid layer at no less than seventy percent by weight of the airlaid layer, and the synthetic binder fibers are present within the airlaid layer at no less than ten percent by weight of the airlaid layer.

12. The absorbent article of claim 1 , wherein the total absorbent capacity of the absorbent article is no greater than three hundred grams.

13. The absorbent article of claim 1 , wherein an intake time of the absorbent article is no less than four seconds and no greater than six seconds.

14. The absorbent article of claim 1 , wherein a ratio of the total absorbent capacity to a dry weight of the absorbent article is from 15:1 to 19:1.

15. An absorbent article, comprising: a top sheet; a back sheet; an absorbent core disposed between the top sheet and the back sheet, the absorbent core comprising a superabsorbent layer with superabsorbent particles present within the superabsorbent layer at no less than ninety percent by weight of the superabsorbent layer; and a core wrap disposed around the absorbent core, the core wrap contacting the top sheet layer, wherein an intake time of the absorbent article is no less than four seconds and no greater than six seconds,KCX-2165-PCT / 65131214PCT02 wherein a water contact angle to the top sheet layer is greater than ninety degrees and less than one hundred and thirty degrees, wherein an air permeability of the core wrap is no less than one thousand, three hundred and fifty cubic meters per hour and no greater than one thousand, five hundred cubic meters per hour, and wherein a basis weight of the top sheet layer is no less than fifteen grams per square meter and no greater than twenty-five grams per square meter, and a basis weight of the core wrap is no less than eighteen grams per square meter and no greater than forty-five grams per square meter.

16. The absorbent article of claim 15, wherein a thickness of the absorbent article between the top sheet and the back sheet at the absorbent core is no less than two millimeters and no greater than four millimeters.

17. The absorbent article of claim 15, wherein a total absorbent capacity of the absorbent article is no less than one hundred grams and no greater than three hundred grams.

18. The absorbent article of claim 15, wherein a pressurized rewet of the absorbent article is no less than five-hundredths gram and no greater than seventeen-hundredths gram.

19. The absorbent article of claim 15, wherein the superabsorbent particles are present within the superabsorbent layer at no less than ninety percent by weight of the superabsorbent layer.

20. The absorbent article of claim 15, wherein a top surface of the core wrap faces towards and is positioned in direct contact with an inner surface of the top sheet.21 . The absorbent article of claim 20, wherein a surge layer is not disposed between the core wrap and the top sheet.

22. The absorbent article of claim 15, wherein a first strikethrough of the top sheet is no less than one and two-tenths seconds and no greater than three and five-tenths seconds.

23. The absorbent article of claim 15, wherein the absorbent core further comprises an airlaid layer with cellulosic fluff bound together with synthetic binder fibers, the airlaid layer disposed on the superabsorbent layer within the core wrap.KCX-2165-PCT / 65131214PCT0224. The absorbent article of claim 23, wherein the cellulosic fluff is present within the airlaid layer at no less than seventy percent by weight of the airlaid layer, and the synthetic binder fibers are present within the airlaid layer at no less than ten percent by weight of the airlaid layer.

25. The absorbent article of claim 15, wherein a ratio of the total absorbent capacity to a dry weight of the absorbent article is from 15:1 to 19:1.

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