Adult diaper having absorbent core with capsuled channels

Abstract

The present invention discloses an adult diaper 100 having a top layer 110, a bottom layer 120 and an absorbent core 130 The absorbent core 130 is embossed 5 to form capsuled channels 170 that are capsule shaped channel patterns throughout the absorbent core 130. The single capsuled channel 170 has a length of 30 mm and breadth of 20 mm. The capsuled channel 170 are arranged longitudinally along the longitudinal direction 140 of the absorbent core and in a horizontal pattern such that the capsules channels 170 are parallel to each other. The capsuled channels 170 10 embossed in the absorbent core 130 facilitate better distribution, spread and quick absorption of liquid in the entire absorbent area.

Description

[0001] “ADULT DIAPER HAVING ABSORBENT CORE WITH CAPSULED CHANNELS”

[0002] FIELD OF THE INVENTION:

[0003] The present invention relates to adult diapers and more particularly to an adult diaper having absorbent core with capsuled channel.

[0004] BACKGROUND OF THE INVENTION:

[0005] Absorbent articles are used to absorb bodily discharges and fluids including urine, blood and feces, oozing surgical wounds, etc. The absorbent articles are therefore developed mainly for personal hygiene and medical use. They come in different forms like diapers, sanitary pads, incontinence products, tampons, adult briefs, medical dressings, towels and sponges.

[0006] Amongst all these absorbent articles, diapers are mainly utilized for infants but are also developed for adults who experience incontinence, for individuals who are bedridden or have mobility issues due to physical disabilities or undergoing medical treatment that affect bladder or bowel control. The adult diapers are similar to infant diapers but are larger in size and have a greater liquid absorbing capacity than infant diapers. Further adult diapers are required to prevent sagging, leakage, and core collapse under higher loads.

[0007] Adult diapers come in different styles such as tab-style diapers and pull up style diapers. Tab style diapers are fastened with adhesive tabs on the sides, making them adjustable and easier to put on and take off. Pull-up style diapers are pulled up and down and utilized by individuals who are capable of mobility. The diapers known in the art generally have five components including a top layer, an acquisition layer, a distribution layer, an absorbent core and a back sheet. The top layer is permeable to liquid and is sometimes further characterized by embossed designs and patterns. The acquisition layer is generally made up of non-woven material mainly polyethylene or polyester fibers. The distribution layer is present between top layer and absorbent core allowing uniform distribution of liquid laterally through the non-woven mesh structure. The absorbent core is characterized by Superabsorbent pulp (SAP) and cellulosic fluff. The back sheet is impermeable to liquid by means of its hydrophobic material hence, does not allow liquid to percolate through it.

[0008] The main objective of adult diaper development is the even distribution of the liquid absorbed in the absorbent core, throughout the core area to avoid sagging and also to prevent leakage from the diaper to provide comfort and dryness to the user.

[0009] To overcome the problem of sagging and leakage from diaper, various techniques are employed including embossing patterns and textures on the top layer of diaper that comes in contact with skin. Another technique includes forming channels that is indentations and grooves in the absorbent core. The channel cores provide improved core performance.

[0010] The prior art suggest that the diapers are developed taking infant usage into account. Therefore, the embossed channels are limited to the crotch area, where the absorbent materials are contained in the tubular zones formed by these channels. Channels in the absorbent core that provides enhanced core integrity, reduced core cracking, better fluid circulation, and less bulking and sagging are limited in the art.

[0011] The PCT application WO2023117032A1 to Sohl Josefin and others describes a disposable hygiene article with embossed absorbent core having a non- continuous embossing line along perimeter of the absorbent article formed of a plurality of discrete embossing points embossed along top sheet downward into the absorbent core covering 7-10 % of absorbent area. However, non-continuous embossing does not serve the purpose of uniform distribution of liquid. Rather it leads to absorption of the fluid in particular area of the core region causing sagging of the core, leading to leakage.

[0012] The United States Patent US11266542B2 to Bewick- Sonntag and others describes an absorbent article with conforming features of various shapes such as diamonds, circles, etc. embossed in the core at the target area. It further includes an acquisition / distribution laminate web facilitating liquid acquisition by the article allowing the inner surface to dry easily. However, the conforming features at target area do not facilitate uniform distribution of the fluid throughout the entire area of the core.

[0013] As an absorbent article is extended longitudinally and has a predefined breadth and depth as per the configuration of the diaper for managing adult incontinence; there is a need of an adult diaper that facilitates uniform fluid distribution throughout the length of the absorbent core of the adult diaper.

[0014] SUMMARY OF THE INVENTION: The present invention relates to an adult diaper having absorbent core with capsuled channels. The adult diaper includes a top layer, a bottom layer, an absorbent core, an acquisition and distribution layer and a core wrap. The top layer is permeable to liquids and is the surface layer present near the skin of the wearer. The bottom layer is positioned at the bottom side of the adult diaper and is made up of a hydrophobic film.

[0015] The absorbent core is present between the top layer and the bottom layer. The absorbent core includes a plurality of capsule-shaped embossed channels extending throughout substantially an entire absorbent area of the absorbent core. The capsule-shaped channels are longitudinally oriented and arranged parallel to each other. The channels define low-absorbency regions that are configured to promote longitudinal and lateral distribution of liquid within the absorbent core and maintain the structural integrity of the absorbent core under load.

[0016] The acquisition and distribution layer is disposed between the top layer and the absorbent core. The absorbent core is encapsulated within the core wrap for maintaining the structural integrity of the absorbent core during use.

[0017] The length of each capsule channel is 30 mm, and the breadth is 20 mm. The absorbent core is prepared from a composite material formed from cellulose fluff pulp having weight of 100-250 gsm and superabsorbent polymer (SAP) having 30-50% by weight of the composite.

[0018] The capsule channels are incorporated by mechanical embossing such that the rollers or plates engage the absorbent core along predetermined longitudinal paths to compress and thermally bond the material to form low-absorbency capsule shaped channels. The embossing operation is performed at a temperature of approximately 85°C and under a pressure of about 600 psi. The embossed channels are in upside-down pattern covering the full area of the absorbent core.

[0019] The top layer of the adult diaper is made of porous propylene layer selected from the grades of SSS, SMS, and SSMMS. The bottom layer is made from a composite of polyethylene (PE) film and nonwoven material selected from a hydrophobic polyethylene film or the like, and a thin polypropylene layer is added for imparting breathability to the bottom layer.

[0020] The acquisition distribution layer is prepared from material selected from high loft chemically bonded or air laid nonwoven fabric, thermal bonded or carded nonwoven fabric, synthetic fiber blends with rayon or viscose, and air laid pulp sheets. The core wrap 160 is prepared from material selected from cellulose tissue or lightweight air laid nonwoven material.

[0021] The process of preparing the adult diaper 100 having absorbent core with capsuled channels includes a first step of preparation of fluff pulp, a second step of defibration, a third step of mixing with super absorbent polymer (SAP), a fourth step of core formation, a fifth step of application of lower wrap layer, a sixth step of application of top wrap layer, a seventh step of embossing, an eighth step of application of acquisition and distribution layer, and a ninth step of formation of finished adult diaper.

[0022] The first step of preparation of fluff pulp includes supplying fluff pulp typically derived from wood cellulose in the form of a compressed sheet or bale form to form the primary absorbent matrix of the diaper. The second step of defibration includes feeding the fluff pulp into a crusher mill or hammer mill for mechanical defibration for breaking down the compressed pulp into individual cellulose fibers, increasing the surface area and absorbency.

[0023] The third step of mixing with super absorbent polymer (SAP) includes homogenous mixing of the defibrated fluff fibers with super absorbent polymer (SAP) particles for enhancing the liquid retention capacity. The fourth step of core formation includes depositing the fluff-SAP mixture onto a core forming drum using vacuum assistance for shaping the absorbent material into a predetermined core geometry.

[0024] The fifth step of application of lower wrap layer with hot melt adhesive includes applying a lower wrap layer beneath the formed absorbent core by spraying hot melt adhesive onto the tissue to secure the absorbent core in place. The sixth step of application of top wrap layer with hot melt adhesive includes placing a top wrap layer over the absorbent core and again applying hot melt adhesive for bonding the top wrap layer to the core and lower wrap layer for encapsulating the absorbent core in the core wrap.

[0025] The seventh step of embossing includes passing the layered structure of top wrap layer, absorbent core and lower wrap layer through mechanical embossing assembly having engraved embossing rollers or plates. The eighth step of application of acquisition distribution layer with hot melt adhesive includes laminating the acquisition distribution layer (ADL) onto the embossed absorbent. The ninth step of formation of finished adult diaper includes integrating the absorbent structure with the top layer and bottom layer; incorporating additional components including elastic elements, fasteners, or wings; followed by cutting, shaping, and folding the composite web to form the final adult diaper.

[0026] The adult diaper having capsuled channels in the absorbent core has improved core integrity and the embossed capsuled channels promote efficient fluid transfer.

[0027] BRIEF DESCRIPTION OF DRAWINGS:

[0028] The objectives and advantages of the present invention will become apparent from the following description read in accordance with the accompanying drawings wherein,

[0029] FIG. 1 depicts an exploded view of the layers of the adult diaper with capsuled channels in the absorbent core in accordance with the present invention;

[0030] FIG. 2 shows the dimensions of the capsuled channels of the absorbent core of the adult diaper of FIG. 1 ; and

[0031] FIG. 3 shows a perspective view of the capsuled channels of the absorbent core of the adult diaper of FIG. 1.

[0032] DESCRIPTION OF THE INVENTION:

[0033] References in the specification to "one embodiment" or "an embodiment" means that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

[0034] References in the specification to “preferred embodiment” means that a particular feature, structure, characteristic, or function described in detail thereby omitting known constructions and functions for clear description of the present invention.

[0035] The foregoing description of specific embodiments of the present invention has been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed and obviously many modifications and variations are possible in light of the above teaching.

[0036] The present invention relates to an adult diaper with capsuled channels in the absorbent core. The diaper developed for managing adult incontinence in accordance with the present invention has capsuled channels embossed exactly below the top sheet of diaper in the absorbent core.

[0037] Referring to FIG. 1, FIG. 2 and FIG. 3, an adult diaper with capsuled channels in the absorbent core 100 hereinafter referred to as ‘adult diaper 100’ is described. The adult diaper 100 includes a top layer 110, a bottom layer 120 and an absorbent core 130. The absorbent core 130 is an elongated rectangular structure extended horizontally. The absorbent core 130 has a longitudinal direction 140 (not shown in the FIGS) along the length of the absorbent core 130, and a transverse direction 145 (not shown in the FIGS) along the breadth of the absorbent core. The absorbent core 130 is snugly positioned between the top layer 110 and bottom layer 120.

[0038] The top layer 110 of the adult diaper 100 is permeable to liquids and is the surface layer present near the skin of the wearer. The bottom layer 120 is positioned at the bottom side of the adult diaper 100. The bottom layer 120 is made up of a hydrophobic film.

[0039] The adult diaper 100 further includes an acquisition distribution layer (ADL) 150. The acquisition and distribution layer 150 is disposed between the top layer 110 and the absorbent core 130. The absorbent core 130 is further encapsulated within a core wrap 160 that maintains the structural integrity of the absorbent core during use.

[0040] The absorbent core 130 is further characterized by a uniform embossed pattern having elongated capsule shape 170, hereinafter referred to as ‘capsuled channels 170’. The absorbent core 130 contains several capsuled channels 170 uniformly embossed throughout the absorbent core. The capsuled channels 170 are arranged longitudinally along the longitudinal direction 140 of the absorbent core 130 and in a horizontal pattern such that the capsuled channels 170 are parallel to each other.

[0041] The top layer 110 is made of porous propylene layer that is soft to the skin of the user. The porous propylene layer is selected from the grades of SSS, SMS, and SSMMS. The SSS grade top layer is a three-layered structure having spun bound + spun bound + spun bound material. The SMS grade top layer is a threelayered structure having spun bound + melt blown + spun bound material. The SSMMS grade top layer is a five-layered structure having three spun bound layers interlaid with two melt blown layers.

[0042] The material used for bottom layer is made from a composite of polyethylene (PE) film and nonwoven material such as a hydrophobic polyethylene film or the like. A thin polypropylene layer is used for imparting breathability to the bottom layer as the layer is impermeable to liquids to retain the liquid.

[0043] The material for the acquisition distribution layer 150 is selected from high loft chemically bonded or air laid nonwoven fabric; thermal bonded or carded nonwoven fabric; synthetic fiber blends with rayon or viscose; air laid pulp sheets and the like. The core wrap 160 is prepared from cellulose tissue; or lightweight air laid nonwoven material, and the like.

[0044] The absorbent core 130 includes a composite material formed from cellulose fluff pulp having weight of approximately 100-250 gsm (grams per square meter) and superab sorbent polymer (SAP) having weight of approximately 30-50% by weight of the composite. This composite material of the absorbent core enables rapid absorption and immobilization of the free liquid components present in the urine and the fecal matter, thereby increasing the viscosity and reducing the mobility of the fecal mass. This limits smearing, lateral migration, and leakage.

[0045] In alternate embodiments, the composite material is selected from tissue SAP composites, air laid absorbent sheets, nonwoven-SAP matrix structures, and the like.

[0046] In accordance with the preferred embodiment of the present invention, the capsuled channels 170 are incorporated by techniques including mechanical embossing and the like. The process of incorporation of channels in the absorbent core 130 by embossing includes subjecting the absorbent core consisting of a homogeneous mixture of cellulose fluff pulp and superab sorbent polymer (SAP) to heated, patterned compression rollers or plates. The rollers or plates engage the absorbent core along the longitudinal paths to compress and thermally bond the material to form low-absorbency ‘capsule shaped channels.’ The embossed channels are in upside-down pattern covering the full area of the absorbent core. Embossing and bonding maintain material continuity and provides fluid-direction through the capsuled channels within the absorbent structure.

[0047] Now, a process of preparing the adult diaper 100 with capsuled channels in the absorbent core 130 is described. The process includes a first step of preparation of fluff pulp, a second step of defibration, a third step of mixing with super absorbent polymer (SAP), a fourth step of core formation, a fifth step of application of lower wrap layer, a sixth step of application of top wrap layer, a seventh step of embossing, an eighth step of application of acquisition and distribution layer, and a ninth step of formation of finished adult diaper.

[0048] In the first step of preparation of fluff pulp, the fluff pulp that is typically derived from wood cellulose is supplied in the form of a compressed sheet or bale form and serves as the primary absorbent matrix of the diaper.

[0049] In the second step of defibration in crusher mill, the fluff pulp is fed into a crusher mill or hammer mill for mechanical defibration. The mill breaks down the compressed pulp into individual cellulose fibers, increasing the surface area and absorbency. This ensures uniform fiber distribution in the absorbent core. In the third step of mixing with super absorbent polymer (SAP), the defibrated fluff fibers are mixed with super absorbent polymer (SAP) particles. SAP is homogenously mixed with the fluff matrix to enhance the liquid retention capacity. The mixture is controlled to achieve a desired fluff-to-SAP ratio depending based on the requirement of diapers for adult incontinence.

[0050] In the fourth step of core formation, the fluff-SAP mixture is deposited onto a core forming drum using vacuum assistance. The drum shapes the absorbent material into a predetermined core geometry selected from rectangular, contoured, anatomical or the like. Vacuum suction ensures uniform thickness and density across the absorbent core.

[0051] In a fifth step of application of lower wrap layer with hot melt adhesive, the lower wrap layer 160 is applied beneath the formed absorbent core. Hot melt adhesive is sprayed onto the tissue to secure the absorbent core in place. This layer provides structural integrity and prevents the fiber migration.

[0052] In a sixth step of application of top wrap layer with hot melt adhesive, the top wrap layer 160 is placed over the absorbent core. Hot melt adhesive is again applied to bond the top wrap layer to the core and lower wrap layer. Together, the top and lower wrap layer encapsulate the absorbent core, forming a core sandwich structure in the core wrap.

[0053] In a seventh embossing step, the layered structure including the top wrap layer, absorbent core, and lower wrap layer is passed through a mechanical embossing assembly having engraved embossing rollers or plates. The rollers or plates engage the layered structure along predetermined longitudinal paths to locally compress and thermally bond the material, thereby forming low-absorbency, capsule-shaped channels within the absorbent core. The embossing operation is performed at a temperature of approximately 85°C and under a pressure of about 600 psi.

[0054] In an eighth step of application of acquisition distribution layer with hot melt adhesive, the acquisition distribution layer (ADL) 150 is laminated onto the embossed absorbent structure using hot melt adhesive. The adhesive application ensures secure bonding without blocking the fluid flow.

[0055] In a ninth step of formation of finished adult diaper, the absorbent structure is integrated with the top layer 110 and bottom layer 120. Depending on the product requirement, additional components including elastic elements, fasteners, or wings are incorporated. The composite web is cut, shaped, and folded to form the final adult diaper.

[0056] In accordance with the preferred embodiment of the present invention, the adult diaper 100 having ‘medium’ size is preferably 775 mm in length and 590 mm in width. The length of the absorbent core 130 is preferably 460 mm along the longitudinal direction 140. The breadth of the absorbent core 130 is preferably 170 mm along the transverse direction 150. The capsule channel 170 has predefined dimensions. The length of a capsuled channel is 30 mm, and the breadth is 20 mm.

[0057] EXAMPLES: Only a few examples and implementations are disclosed. Variations, modifications, and enhancements to the described examples and implementations and other implementations can be made based on what is disclosed.

[0058] Examples are set forth herein below and are illustrative of different amounts and types of reactants and reaction conditions that can be utilized in practicing the disclosure. It will be apparent, however, that the disclosure can be practiced with other amounts and types of reactants and reaction conditions than those used in the examples, and the resulting devices various different properties and uses in accordance with the disclosure above and as pointed out hereinafter.

[0059] EXAMPLE 1: DIMENSIONS OF THE ADULT DIAPER IN VARIOUS SIZES

[0060] Table 1 below provides the dimensions of the adult diaper 100 across various sizes.

[0061] EXAMPLE 2: DEMONSTRATION OF IMPROVED ABSORPTION RATE

[0062] AND PAD INTEGRITY OF THE ADULT DIAPER HAVING CAPSULED

[0063] CHANNELS Example 2a: Adult diaper with capsuled channel vs Adult diaper without capsuled channel

[0064] Objective:

[0065] To evaluate the technical efficacy of the adult diaper 100 having capsuled channels, a comparative laboratory testing was conducted against adult diaper without capsuled channels. The tests were performed under controlled conditions in accordance with the standard test protocol IS 17509:2021, prescribing the procedures for assessing the absorption rate of the adult diaper.

[0066] Test Parameters and methodology:

[0067] A. Sample Sizes:

[0068] Adult diaper with capsuled channel vs Adult diaper without capsuled channel

[0069] B. Tested Parameters:

[0070] 1. Absorption rate: time (seconds) required to completely absorb a defined liquid insult under specified test conditions

[0071] 2. Pad integrity (break) cycle: the number of repeated mechanical stress cycles the pad can withstand before structural failure occurs

[0072] C. Test - Standard test for Absorption rate:

[0073] Procedure:

[0074] 1 ) The adult diaper was placed flat on the test platform with the topsheet facing upward.

[0075] 2) A fixed volume of liquid was dispensed onto the surface at a constant rate.

[0076] 3) The liquid was observed until it is no longer visible on the surface and no free liquid remains. 4) Multiple test samples were assessed and the average absorption rate was calculated.

[0077] D. Test - Standard test method for pad integrity

[0078] Equipments and materials: IULTCS fastener tester, Balance, Scissor, Beaker, Ruler, Timer, Measuring cylinder, Stainless steel dosing ring 50mm diameter.

[0079] Working procedure:

[0080] • 0.9% NaCl saline solution with distilled water was prepared and food grade color was added.

[0081] • IULTCS fastener tester was switched on. 3 samples of diapers were collected and their weight was recorded.

[0082] • The leg, cuff and panel elastics were removed without disturbing the core or its supporting material.

[0083] • The centre point of the full diaper and a point 50mm towards the front of the diaper was marked.

[0084] • The required quantity of solution was measured in measuring cylinder based on diaper size as follows:

[0085] • The dosing ring was held centrally over the marked point of the diaper, and the saline was poured in the centre of the cylinder, and the stopwatch was started. • After 15 minutes, the diaper was clamped in IULTCS fastener tester.

[0086] • The zero button was pressed to reset the counter and the speed was set to 38 cycle / min (the drop height to 20mm high).

[0087] • The start button was pressed on the IULTCS fastener tester.

[0088] • Test was run until a full crack is visible across the diaper and the number of drops before breakage were recorded.

[0089] • The procedure was repeated for remaining two samples and an average of the three readings was recorded.

[0090] Note: The average number of drops before breakage should be greater than 20 drops.

[0091] Experimental Results:

[0092] Observations and Inference:

[0093] 1. The absorption rate improved significantly, decreasing from 40 seconds without the capsuled channel to 29 seconds with the capsuled channel, indicating faster liquid intake and more efficient acquisition at the point of insult. This enhanced intake reduces surface wetness and improves user comfort.

[0094] 2. The liquid distribution length increased from 260 mm to 300 mm, showing that the capsuled channel promotes more effective lateral spreading of fluid. 3. The pad integrity - break cycle value increased markedly from 46 cycles in adult diaper without capsuled channel to 82 cycles in adult diaper having capsuled channel. This demonstrated improvement in mechanical strength and structural stability. This indicates stronger bonding between layers, reduced delamination, and greater resistance to deformation under repeated mechanical stress during use.

[0095] Example 2b: Adult diaper with capsuled channel vs Market sample of adult diaper Objective:

[0096] To evaluate the technical efficacy of the adult diaper 100 having capsuled channels, a comparative laboratory testing was conducted against adult diaper from market. The tests were performed under controlled conditions in accordance with the standard test protocol IS 17509:2021, prescribing the procedures for assessing the absorption rate of the adult diaper.

[0097] Test Parameters and methodology:

[0098] A. Sample Sizes:

[0099] Adult diaper with capsuled channel vs commercially available adult diaper in market

[0100] B. Tested Parameters:

[0101] 1. Absorption rate: time (seconds) required to completely absorb a defined liquid insult under specified test conditions

[0102] 2. Pad integrity (break) cycle: the number of repeated mechanical stress cycles the pad can withstand before structural failure occurs

[0103] C. Test- Standard test for Absorption rate D. Test- Standard test method for pad integrity

[0104] Experimental Results:

[0105] Observations and Inference:

[0106] 1) The adult diaper with capsuled channel exhibited a lower absorption rate of 29 seconds compared to 36 seconds for the commercially available adult diaper. This indicates faster liquid uptake and improved fluid acquisition efficiency, which helps reduce surface wetness and enhances immediate wearer comfort.

[0107] 2) The liquid distribution length increased from 259 mm in the commercially available diaper to 300 mm in the capsuled channel diaper. The capsuled channels promote better lateral spreading of liquid, enabling more uniform utilization of the absorbent core and reducing the likelihood of localized saturation and leakage.

[0108] 3) The pad integrity improved significantly, with break cycles increasing from 58 cycles to 82 cycles in the diaper with capsuled channels. This demonstrates enhanced mechanical bonding and structural stability of the absorbent core, resulting in greater resistance to delamination and improved durability during use. EXAMPLE 3: DEMONSTRATION OF REDUCED WETNESS AND

[0109] ENHANCED DRYNESS IN ADULT DIAPER

[0110] Objective:

[0111] To conduct laboratory tests to assess the surface wetness and dryness performance of the adult diaper 100 with capsuled channels. The evaluation was carried out under controlled conditions in accordance with IS 17509:2021, the standard protocol for testing disposable absorbent articles.

[0112] Objective: To quantify and compare the residual surface moisture (rewet) after absorption, which correlates directly with user-perceived dryness.

[0113] Test Parameters and methodology:

[0114] A. Sample Sizes:

[0115] Adult diaper with capsuled channels vs Adult diaper without capsuled channels

[0116] B. Tested Parameters:

[0117] Residual surface moisture (rewet) after absorption

[0118] C: Procedure:

[0119] 1. Three successive fluid gushes were introduced into each product at defined intervals.

[0120] 2. After full absorption of each gush, a standard weight and filter paper were placed on the product surface.

[0121] 3. The amount of fluid transferred to the filter paper was recorded as the rewet value (grams) - lower values indicate enhanced surface dryness.

[0122] Experimental Results:

[0123] Observations:

[0124] The adult diaper with capsuled channels shows a significantly lower rewet value of 0.12 g compared to 0.30 g for the adult diaper without capsuled channels. The substantially reduced rewet indicates superior liquid retention and faster transfer of fluid into the absorbent core in the capsuled channel diaper. This results in a drier surface after absorption, thereby improving skin dryness, hygiene, and overall wearer comfort.

[0125] Advantageously, the capsuled channels 170 embossed along the full area of the absorbent core 130 of the adult diaper allows better distribution and spread of the fluid that facilitates quick absorption of the fluid in the entire absorbent area. The adult diaper 100 having capsuled channels 170 ensure effective absorption and containment. The process of embossing enhances mechanical bonding between tissue layers and the absorbent core, thus improving the core integrity, stability, and resistance to delamination. The embossed capsuled channels promote efficient fluid transfer, reduce the bulk while maintaining absorbency, and increase the flexibility and wearer comfort. Further, the upper layer remains dry giving comfort to the wearer.

[0126] The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others, skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated.

[0127] It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present invention.

Claims

1. CLAIMS:

1. An adult diaper 100 having absorbent core with capsuled channels, comprising: a top layer 110 permeable to liquids and being the surface layer present near the skin of the wearer; a bottom layer 120 positioned at the bottom side of the adult diaper 100 and being made up of a hydrophobic film; an absorbent core 130 disposed between the top layer and the bottom layer, wherein the absorbent core 130 being characterized by a plurality of capsule-shaped embossed channels 170 extending throughout substantially an entire absorbent area of the absorbent core, the capsule-shaped channels being longitudinally oriented and arranged parallel to each other, such that the channels defining low-absorbency regions being configured for promoting longitudinal and lateral distribution of liquid within the absorbent core and for maintaining the structural integrity of the absorbent core under load; an acquisition and distribution layer 150 being disposed between the top layer 110 and the absorbent core 130; and a core wrap 160 such that the absorbent core 130 being encapsulated within the core wrap 160 for maintaining the structural integrity of the absorbent core during use.

2. The adult diaper 100 having absorbent core with capsuled channels as claimed in Claim 1, wherein the length of each capsule channel being 30 mm, and the breadth being 20 mm.

3. The adult diaper 100 having absorbent core with capsuled channels as claimed in Claim 1, wherein the absorbent core 130 being prepared from a composite material formed from cellulose fluff pulp having weight of 100- 250 gsm and superabsorbent polymer (SAP) having 30-50% by weight of the composite.

4. The adult diaper 100 having absorbent core with capsuled channels as claimed in Claim 1, wherein the capsule channels 170 being incorporated by mechanical embossing such that the rollers or plates engaging the absorbent core along predetermined longitudinal paths to compress and thermally bond the material to form low-absorbency capsule shaped channels; the embossing operation being performed at a temperature of approximately 85°C and under a pressure of about 600 psi; and the embossed channels being in upside-down pattern covering the full area of the absorbent core.

5. The adult diaper 100 having absorbent core with capsuled channels as claimed in Claim 1, wherein the top layer 110 being made of porous propylene layer selected from the grades of SSS, SMS, and SSMMS, andthe bottom layer being made from a composite of polyethylene (PE) film and nonwoven material selected from a hydrophobic polyethylene film or the like, and a thin polypropylene layer being added for imparting breathability to the bottom layer.

6. The adult diaper 100 having absorbent core with capsuled channels as claimed in Claim 1, wherein the acquisition distribution layer 150 being prepared from material selected from high loft chemically bonded or air laid nonwoven fabric, thermal bonded or carded nonwoven fabric, synthetic fiber blends with rayon or viscose, and air laid pulp sheets; and the core wrap 160 being prepared from material selected from cellulose tissue or lightweight air laid nonwoven material.

7. A process of preparing the adult diaper 100 having absorbent core with capsuled channels of Claim 1, including: a) a first step of preparation of fluff pulp including supplying fluff pulp typically derived from wood cellulose in the form of a compressed sheet or bale form to form the primary absorbent matrix of the diaper; b) a second step of defibration including feeding the fluff pulp into a crusher mill or hammer mill for mechanical defibration for breaking down the compressed pulp into individual cellulose fibers, increasing the surface area and absorbency;c) a third step of mixing with super absorbent polymer (SAP) including homogenous mixing of the defibrated fluff fibers with super absorbent polymer (SAP) particles for enhancing the liquid retention capacity; d) a fourth step of core formation including depositing the fluff-SAP mixture onto a core forming drum using vacuum assistance for shaping the absorbent material into a predetermined core geometry; e) a fifth step of application of lower wrap layer with hot melt adhesive including applying a lower wrap layer beneath the formed absorbent core by spraying hot melt adhesive onto the tissue to secure the absorbent core in place; f) a sixth step of application of top wrap layer with hot melt adhesive including placing a top wrap layer over the absorbent core and again applying hot melt adhesive for bonding the top wrap layer to the core and lower wrap layer for encapsulating the absorbent core in the core wrap; g) a seventh step of embossing including passing the layered structure of top wrap layer, absorbent core and lower wrap layer through mechanical embossing assembly having engraved embossing rollers or plates; h) an eighth step of application of acquisition distribution layer with hot melt adhesive including laminating the acquisition distribution layer (ADL) onto the embossed absorbent; and i) a ninth step of formation of finished adult diaper by integrating the absorbent structure with the top layer and bottom layer; incorporating additional components including elastic elements, fasteners, or wings;followed by cutting, shaping, and folding the composite web to form the final adult diaper.

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