Absorbent article with improved bottom distribution assembly

Abstract

An absorbent article comprising a liquid pervious topsheet (300), a liquid impervious backsheet (200), absorbent material (130) positioned between the liquid pervious topsheet and the liquid impervious backsheet, and a bottom distribution assembly (120) between the absorbent material and the liquid impervious backsheet, wherein the absorbent material (130) comprises cellulosic fluff pulp (131) and first superabsorbent particles (132) and is arranged such that one or more channels (160, 170) are formed, wherein less absorbent material per surface area is present in the one or more channels compared to an area around the one or more channels, wherein preferably substantially no absorbent material is present in the one or more channels, wherein the bottom distribution assembly comprises a first nonwoven (121), wherein the first nonwoven (121) comprises second superabsorbent particles (142).

Description

[0001] ABSORBENT ARTICLE WITH IMPROVED BOTTOM DISTRIBUTION ASSEMBLY

[0002] TECHNICAL FIELD

[0003] The present invention pertains to the technical field of absorbent articles, more preferably disposable personal care articles such as diapers, baby pants, adult incontinent garments, and the like, and to absorbent structures for use in such absorbent articles. More specifically the present invention relates to an absorbent article comprising one or more channels. The present invention also relates to methods for manufacturing such an absorbent article.

[0004] BACKGROUND

[0005] Absorbent articles comprising an absorbent core with one or more channels between a topsheet and a backsheet are well known. Examples of such absorbent articles are described for example in patents EP 3 403 630 Bl, EP 3 403 632 Bl and EP 3 403 631 Al in the name of the applicant, which are incorporated herein by reference. Such channels may provide for core integrity both in the dry and the wet state as typically the top core wrap sheet is attached to the back core wrap sheet at least in a portion of the one or more channels. Further, the one or more channels provide for fast liquid distribution by mass flow. This effect is increased as the absorbent article is wetted and the absorbent material around the one or more channels swells.

[0006] It is further known to provide a liquid distribution and acquisition layer (ADL) between the topsheet and the absorbent core in order to temporarily take up and distribute the liquid from the topsheet towards the absorbent core. Typically, an ADL extends over an area where liquid insult is to be expected. Known ADL layers have the disadvantage that it takes some time before a dry feeling is obtained at the topsheet surface and that rewetting can be significant.

[0007] Also, European patent application EP20156457.2 in the name of the applicant, which is here incorporated by reference, discloses to add a capillary acceleration sheet between the top core wrap sheet and the topsheet, or to replace the top core wrap sheet with a capillary acceleration sheet. Combining at least one channel with such relatively thin capillary acceleration sheet ensures a fast dryness feeling and a low rewetting at the level of the topsheet, whilst at the same time providing a good liquid distribution through the one or more channels resulting in improved leakage protection. Thus, the capillary acceleration sheet pulls liquid to the absorbent material in a very fast manner, resulting in a fast dryness at top sheet level.Further, it is known to include a liquid-impermeable, either hydrophilic or hydrophobic, distribution or wicking layer which helps to wick and transport liquids and having a capability to disperse the liquid over the surface of said wicking layer from the less absorbent areas (e.g. saturated areas) to the more absorbent areas (e.g. unsaturated areas). The distribution layer or wicking layer is preferably located at the garment facing side of the absorbent core. Due to the specific absorbent capacity of the distribution or wicking layer, the liquid in the one or more channels will be drawn up into the distribution layer and will spread out throughout the rest of the distribution layer. In that way, the distribution, transport and absorption of the liquid can be improved.

[0008] SUMMARY

[0009] The object of embodiments of the invention is to provide an absorbent article of the type stated in the preamble, with an improved bottom distribution and / or storage of liquid.

[0010] According to a first aspect of the invention, there is provided an absorbent article comprising a liquid pervious topsheet, a liquid impervious backsheet, absorbent material positioned between the liquid pervious topsheet and the liquid impervious backsheet, and a bottom distribution assembly between the absorbent material and the liquid impervious backsheet. The absorbent material comprises cellulosic fluff pulp and first superabsorbent particles. The absorbent material is arranged such that one or more channels are formed, wherein less absorbent material per surface area is present in the one or more channels compared to an area around the one or more channels, wherein preferably substantially no absorbent material is present in the one or more channels. The bottom distribution assembly comprises a first nonwoven and the first nonwoven comprises second superabsorbent particles.

[0011] By including second superabsorbent particles in the first nonwoven, the first nonwoven can not only function as distribution layer, but also provides additional storage capabilities. The liquid in the one or more channels may be distributed to the absorbent material via the first nonwoven and / or via further optional nonwovens (see further), wherein a portion of the liquid may also be stored in the second absorbent particles whilst being transported to the absorbent material.

[0012] Preferably, the second superabsorbent particles are included in pores of the first nonwoven. Preferably substantially no cellulosic fluff pulp is present in the first nonwoven.

[0013] Preferably, the first nonwoven is in direct contact with the absorbent material. However, in some embodiments the bottom distribution assembly may comprise an additional nonwoven between the absorbent material and the first nonwoven, for example in order to improve the distribution.Preferably, one or more physical and / or chemical properties of the first superabsorbent particles and second superabsorbent particles are different, wherein more preferably the chemical properties are different. The physical properties comprise the dimensions and the shape of the particles. The dimensions of the second superabsorbent particles may for example be adapted to fit well within the first nonwoven material. Further, the chemical properties, related to the chemical composition of the superabsorbent particles may be adjusted depending on the desired storage functionalities of the absorbent material layer on the one hand, and the distribution and storage functionalities in the first nonwoven on the other hand.

[0014] Preferably, the centrifuge retention capacity, CRC, of the first superabsorbent particles and the CRC of the second superabsorbent particles are different, wherein preferably the difference is at least 2g / g, more preferably at least 3g / g even more preferably at least 4g / g. CRC is a value indicating how much water is retained after dewatering the swollen SAP with a centrifuge. By using different CRC values the storage and distribution properties can be optimised.

[0015] In an advantageous embodiment, the CRC of the first superabsorbent particles is lower than the CRC of the second super absorbent particles, preferably at least 4g / g lower. The CRC in the absorbent material can be lower because of the one or more channels and the first nonwoven which promote distribution and because the CRC in the first nonwoven is higher.

[0016] However, in other embodiments, the CRC of the first superabsorbent particles may be higher than the CRC of the second superabsorbent particles for example because such SAP material is cheaper and / or is more appropriate to be included in the first nonwoven.

[0017] Preferably, the vortex of the first superabsorbent particles and the vortex of the second superabsorbent particles are different, wherein preferably the difference is at least 10s, more preferably at least 15s even more preferably at least 20s. The vortex is a measure for how fast liquid is being absorbed and showing gel like behaviour.

[0018] In an advantageous embodiment, the vortex of the first superabsorbent particles is lower than the vortex of the second superabsorbent particles, preferably at least 10s lower, more preferably at least 15s lower, even more preferably at least 20s lower. In this way liquid will be absorbed faster in the first superabsorbent particles in the absorbent material than in the second absorbent particles in the first nonwoven, so that the distribution properties of the first nonwoven are maintained to a suitable level for a longer period of time.Preferably, the absorption against pressure, AAP of the first superabsorbent particles and the AAP of the second superabsorbent particles are different, wherein preferably the difference is at least 2g / g, more preferably at least 3g / g, measured at 4.8 kPa.

[0019] In an advantageous embodiment, the AAP of the first superabsorbent particles is higher than the AAP of the second superabsorbent particles, preferably at least 2g / g higher, more preferably at least 3g / g higher, measured at 4.8 kPa. By including first superabsorbent particles with a higher APP in the absorbent material, the amount of liquid that escapes from the first superabsorbent particles in case of pressure, such as when a person sits, will be limited, and the amount of liquid taken up when a person sits will be increased. This is less critical for the second superabsorbent particles included in the bottom distribution assembly.

[0020] Preferably, an amount (expressed in g) of the first superabsorbent particles in the absorbent material is higher than an amount of the second superabsorbent particles in the first nonwoven. Preferably, at least 1 g of the second superabsorbent particles is included in the first nonwoven, more preferably more than 2g. For example, the absorbent material may include between 2 and 6g cellulosic fluff pulp and between 10 and 14g first superabsorbent polymer particles and the first non wo ven may include between 0.5 and 5g second superabsorbent polymer particles. In another example, the absorbent material may include between 1 and 5g cellulosic fluff pulp and between 5 and 9g first superabsorbent polymer particles and the first nonwoven may include between 3 and 7g second superabsorbent polymer particles.

[0021] In a possible embodiment, the bottom distribution assembly comprises a second nonwoven arranged between the backsheet and the first nonwoven and configured to form a barrier for the second superabsorbent particles. Preferably, the second nonwoven has a second average density which is higher than a first average density of the first nonwoven, wherein a difference between the first average density and the second average density is higher than 20 kg / m3, preferably higher than 30 kg / m3 more preferably higher than 40 kg / m3, even more preferably between 50 and 150 kg / m3, most preferably between 60 and 140 kg / m3. Preferably, the first non wo ven has an average density between 20 and 400 kg / m3, more preferably between 20 and 300 kg / m3, even more preferably between 20 and 250 kg / m3; and / or the second non wo ven has an average density between 50 and 400 kg / m3. Preferably, the second non woven has a basis weight between 8 and 60 g / m2, preferably between 10 and 50 g / m2. Preferably, the second non wo ven comprises a spunbond and / or a meltblown layer. Alternatively, the second nonwoven may be a carded thermobonded nonwoven. Preferably, the second nonwoven comprises polypropylene PP.Such second nonwoven has the advantage of providing an improved softness in the dry state and / or an improved core integrity in the dry and / or wet state.

[0022] In another possible embodiment, the bottom distribution assembly comprises a second nonwoven arranged between the backsheet and the first nonwoven and wherein the second nonwoven comprises third superabsorbent particles. Preferably, one or more physical and / or chemical properties of the second superabsorbent particles and third superabsorbent particles are different, wherein preferably the chemical properties are different. Preferably, the centrifuge retention capacity, CRC, and / or the vortex and / or the AAP of the second superabsorbent particles and the centrifuge retention capacity, CRC, and / or the vortex and / or the AAP of the third superabsorbent particles are different.

[0023] Optionally, an amount of the second superabsorbent particles in the first nonwoven is different from an amount of the third superabsorbent particles in the second nonwoven. Preferably, the bottom distribution assembly further comprises a third nonwoven between the second nonwoven and the backsheet, said third nonwoven being preferably configured to form a barrier for the third superabsorbent particles. Preferably, the second nonwoven has a basis weight between 15 and 150 g / m2, preferably between 20 and 130 g / m2.

[0024] Preferably, the first nonwoven is any one of the following: a carded through-air-bonded nonwoven, a spunlace nonwoven.

[0025] Preferably, an amount of the cellulosic fluff pulp in the absorbent material is below 350 g / m2, preferably below 300 g / m2, more preferably below 250 g / m2, even more preferably below 200 g / m2, e.g. between 50 g / m2 and 180 g / m2.

[0026] Preferably, an amount (expressed in g) per surface area of the first superabsorbent particles in the absorbent material is between 100 g / m2 and 350 g / m2.

[0027] Preferably, an amount of the second superabsorbent particles in the absorbent material is above 15 g / m2, more preferably between 20 g / m2 and 200 g / m2.

[0028] Preferably, the first non woven has a basis weight between 15 and 150 g / m2, preferably between 30 and 85 g / m2, more preferably between 35 and 80 g / m2.Preferably, the absorbent article further comprises a top core wrap sheet and / or a capillary acceleration sheet between the absorbent material and the topsheet, wherein the first nonwoven, and optionally also the optional second nonwoven, is attached to the top core wrap sheet and / or the capillary acceleration sheet at least in a portion of the one or more channels.

[0029] Preferably, the first nonwoven, and optionally also the optional second nonwoven if present, is attached along a periphery to the top core wrap sheet and / or the capillary acceleration sheet.

[0030] Preferably, the first nonwoven, and optionally also the optional second nonwoven is glued to the top core wrap sheet and / or the capillary acceleration sheet at least in a portion of the one or more channels.

[0031] Preferably, the first nonwoven, and optionally also the optional second nonwoven is sealed in accordance with a sealing pattern to the top core wrap sheet and / or to the capillary acceleration sheet at least in a portion of the one or more channels, wherein preferably the sealing is realized by heat and / or pressure and / or ultrasonic energy. Optionally, the sealing pattern covers less than 70%, preferably less than 60%, more preferably less than 50%, even more preferably between 1 and 40% of the surface area of the one or more channels.

[0032] Preferably, the first non wo ven is any one of the following non wo vens: a resin bonded non wo ven, an air-through bonded nonwoven, an air-laid nonwoven, a needle bonded nonwoven, a spunbond through air-bond nonwoven, a 3D perforated film, a 3D embossed nonwoven, a hydro-entangled nonwoven, a thermo-carded nonwoven, or a combination thereof. Such layers can provide the required open structure.

[0033] In an exemplary embodiment, the absorbent article further comprises a top core wrap sheet and / or a capillary acceleration sheet between the absorbent material and the topsheet. Typically, only a capillary acceleration sheet is present or a combination of a top core wrap sheet and a capillary acceleration sheet. Preferably, the first nonwoven is attached to the top core wrap sheet and / or the capillary acceleration sheet at least in a portion of the one or more channels. In that manner, a well structured absorbent article is obtained with one or more well defined channels, further improving the liquid guidance by mass flow through the one or more channels, through the first non wo ven to the absorbent material.

[0034] In an exemplary embodiment, the first nonwoven is glued to the top core wrap sheet and / or a capillary acceleration sheet at least in a portion of the one or more channels. For example, adhesivemay be arranged in one or more lanes or in a swirl pattern on the top core wrap sheet and / or the capillary acceleration sheet and / or the first nonwoven, such that the one or more lanes or swirl pattern overlap at least partially with the one or more channels.

[0035] In addition or alternatively, the first nonwoven is sealed in accordance with a sealing pattern to the top core wrap sheet and / or to the capillary acceleration sheet at least in a portion of the one or more channels, wherein preferably the sealing is realized by heat and / or pressure and / or ultrasonic energy. For example, the sealing pattern covers less than 80%, preferably less than 70%, more preferably less than 60%, even more preferably less than 50%, most preferably between 1 and 50% of the surface area of the one or more channels. For example, the sealing pattern covers between 1 and 50% of the total surface area of the one or more channels, or between 1 and 40%, or between 1 and 30%, or between 1 and 25%, or between 2 and 25%, or between 3 and 25%, or between 4 and 25%.

[0036] Such sealing pattern can provide a good resistance against the swell forces generated by liquid being captured in the superabsorbent particles by hydrogen bonds, but the sealing pattern equally can provide resistance against dry and wet superabsorbent particles trying to penetrate through the first nonwoven and through the sealing pattern after as well as during the sealing step of the manufacturing process. In that manner, any risk of dry or wet SAP particles coming into contact with sensitive skin upon wearing is avoided or reduced. Further, by having a reduced surface area that is being sealed in accordance with a pattern, any particles remaining in the one or more channel zones can easily migrate to a non-sealing area so that the risk of creating holes in the one or more channel zones is reduced or avoided.

[0037] Preferably, the sealing pattern is a regular pattern, such as a line pattern such as a grid, a pattern of dots, etc. The dots may have any shape, e.g. round, polygonal, etc. The line pattern may comprise one or more sets of parallel lines. When a first set of parallel lines and a second set of parallel lines is included, the lines of the first set may be oriented at a non-zero angle with respect to the lines of the second set.

[0038] Preferably, the sealing pattern comprises a large number of distinct sealing areas spread across the one or more channels. Preferably, the large number is larger than 10, more preferably larger than 20.

[0039] Preferably, the sealing pattern comprises a plurality of discrete elements, and each discrete element has a first dimension in a first direction and a second dimensions in a direction perpendicular to the first direction. The first dimension is smaller than 2 mm, preferably smaller than 1.5 mm, morepreferably smaller than 1 mm, e.g. between 0.1 and 0.7 mm or between 0.2 and 0.7 mm, or between 0.3 and 0.6 mm.

[0040] By providing well selected sealing patterns, such as grids, dots, polygons, etc., that have a limited total bonding area with fine single bonding areas, e.g. having a surface area smaller than 2 mm2or a line thickness lower than 1 mm, individual superabsorbent particles will find easier their way to nonsealed zones in order not to create any hole.

[0041] In a preferred embodiment, only the capillary acceleration is present between the topsheet and the absorbent material, and the basis weight of the first nonwoven is higher than the basis weight of the capillary acceleration sheet.

[0042] In an exemplary embodiment only the first nonwoven is present between the backsheet and the absorbent material. However, in other embodiments the first nonwoven may be part of a bottom distribution assembly comprising one or more further nonwoven, such as the second and third non wo ven described above.

[0043] In an exemplary embodiment the first nonwoven is attached to the topsheet at least in a portion of the one or more channels. In some embodiments there may be no top core wrap sheet or capillary acceleration sheet, i.e. no additional layer between the topsheet and the absorbent material, and the top sheet may be in direct contact with the absorbent material. The topsheet may then function as a capillary acceleration sheet.

[0044] Preferably, the backsheet has a basis weight below 30 g / m2, preferably below 28 g / m2, e.g. below 26 g / m2 or even below 24 g / m2. Because of the presence of the first nonwoven, the basis weight of the backsheet may be smaller compared to prior art embodiments.

[0045] For determining the density of a non wo ven, the mass per unit area may be measured using NWSP 130.1.R0 (20) and the nonwoven thickness may be measured using NWSP 120.6.R0 (15). The density can then be calculated as the mass per unit area divided by the thickness.

[0046] The capillary acceleration sheet may comprise at least one meltblown layer, preferably a single meltblown layer. The at least one meltblown layer represents between 2 and 30 weight% of the weight of the capillary acceleration sheet, preferably between 3 and 30 weight%, more preferably between 3 and 20 weight%, even more preferably between 3 and 18 weight%. For example, the at least one meltblown layer represents between 3 and 15 weight%, between 3 and 14 weight%,between 3 and 13 weight%, between 3 and 12 weight, between 3 and 11 weight% or between 3% and 10 weight%. In addition or alternatively, the at least one meltblown layer, preferably a single meltblown layer, has a basis weight of less than 6 g / m2, preferably less than 5 g / m2, more preferably less than 4 g / m2, even more preferably less than 3 g / m2, e.g. less than 2 g / m2. For example, the at least one meltblown layer has a basis weight between 0.5 g / m2 and 5 g / m2, or between 0.5 g / m2 and 4 g / m2, between 0.5 g / m2 and 3 g / m2, or between 0.4 g / m2 and 2 g / m2.

[0047] In that way a good topsheet dryness, and in particular a fast topsheet dryness after liquid insult, and a good rewetting behaviour, is obtained, whilst avoiding that absorbent material, and in particular superabsorbent particles, escape from the absorbent article and / or contact the skin of the wearer of the absorbent article. By having a small melt fraction in the capillary acceleration sheet, the absorbent material, and in particular superabsorbent particles can be well maintained in the absorbent article without requiring an adapted topsheet or other layer. On the other hand, since the melt fraction is low, the remaining fraction of the capillary acceleration sheet can fulfil its capillary acceleration function. By combining at least one channel with a capillary acceleration sheet a fast dryness feeling and a low rewetting at the level of the topsheet can be ensured, whilst at the same time providing a good liquid distribution through the one or more channels resulting in improved leakage protection. Also, the topsheet may be an apertured topsheet as the melt fraction of the capillary acceleration sheet will avoid that any significant amounts of absorbent material, and in particular of superabsorbent particles, escape through the topsheet.

[0048] In an exemplary embodiment, the capillary acceleration sheet has a mean flow pore size below a predetermined value, and the absorbent material comprises superabsorbent particles prepared such that substantially no superabsorbent particles having dimensions smaller than said mean flow pore size are present in the absorbent material. By using absorbent material comprising absorbent particles with a well-defined particle size distribution (PDS) adapted to the flow pore size of the capillary acceleration sheet, any escaping of absorbent material through the topsheet can be further reduced. Topping of the fines (e.g. a “dust-fraction” < 50 pm) away may be advantageous, as well as the removal of a large fraction (e.g. >600 pm). For example, traditional blend polymerization superabsorbent particles can serve for this purpose, with sieve selection. According to another example drop polymerization superabsorbent particles (e.g. SAVIVA® superabsorbent of the company BASF) with a narrow PDS can be used. Also, solvent polymerized superabsorbent particles can have such a narrow PDS.

[0049] Preferably, the capillary acceleration sheet consists of a spunbond meltblown nonwoven fabric or a spunbond-meltblown-spunbond nonwoven fabric.Preferably, the capillary acceleration sheet comprises a spunbond layer arranged against the topsheet. For example, the capillary acceleration sheet may consist of a spunbond meltblown nonwoven fabric, SM, with a spunbond layer thereof facing the topsheet and a meltblown layer thereof facing the absorbent material. In an embodiment without a top core wrap sheet, the meltblown layer may be in direct contact with the absorbent material. In an embodiment with a top core wrap sheet, the meltblown layer may be in direct contact with the top core wrap sheet.

[0050] The capillary acceleration sheet may have a mean flow pore size below 50 micron, preferably between 5 and 50 micron, more preferably between 10 and 50 micron, e.g. between 10 and 40 micron or between 20 and 40 micron.

[0051] By having a capillary acceleration sheet with a mean flow pore size below 50 micron, the absorbent material, and in particular super absorbent particles can be well maintained in the absorbent article without requiring an adapted topsheet. On the other hand, the capillary acceleration sheet can fulfil its capillary acceleration function, and will allow liquid to pass through the capillary acceleration sheet. By combining at least one channel with a capillary acceleration sheet a fast dryness feeling and a low rewetting at the level of the topsheet can be ensured, whilst at the same time providing a good liquid distribution through the one or more channels resulting in improved leakage protection. Also, the topsheet may be an apertured topsheet as the low mean flow pore size of the capillary acceleration sheet will avoid that any significant amounts of absorbent material, and in particular of superabsorbent particles, escape through the topsheet.

[0052] The measure "mean flow pore size" refers to a measure of average pore diameter as determined by a liquid displacement technique utilizing a Coulter Porometer and Coulter POROFIL® test liquid available from Coulter Electronics Limited, Luton, England. The mean flow pore size is determined by wetting a test sample with a liquid having a very low surface tension (i.e., Coulter POROEIL®). Air pressure is applied to one side of the sample. Eventually, as the air pressure is increased, the capillary attraction of the fluid in the largest pores is overcome, forcing the liquid out and allowing air to pass through the sample. With further increases in the air pressure, progressively smaller and smaller holes will clear. A flow versus pressure relationship for the wet sample can be established and compared to the results for the dry sample. The mean flow pore size is measured at the point where the curve representing 50% of the dry sample flow versus pressure intersects the curve representing wet sample flow versus pressure. The diameter of the pore which opens at that particular pressure (i.e., the mean flow pore size) can be determined from the following expression: pore diameter pm = 40 r / pressure, where r = surface tension of the fluid expressed in units of mN / M;the pressure is the applied pressure expressed in millibars (mbar); and the very low surface tension of the liquid used to wet the sample allows one to assume that the contact angle of the liquid on the sample is about zero.

[0053] The capillary acceleration sheet may have a mean flow pore size below a predetermined value, and the absorbent material comprises superabsorbent particles prepared such that substantially no superabsorbent particles having dimensions smaller than said mean flow pore size are present in the absorbent material.

[0054] By using a capillary acceleration sheet having a mean flow pore size below a predetermined value in combination with absorbent particles with a well-defined particle size distribution (PDS) adapted to the predetermined value, any escaping of absorbent material through the topsheet can be avoided or reduced. For example, traditional blend polymerization superabsorbent particles can serve for this purpose, wherein a sieve selection is used to obtain the desired PDS. According to another example drop polymerization superabsorbent particles (e.g. SA VIVA® superabsorbent of the company BASF) with a narrow PDS can be used. Also solvent polymerized superabsorbent particles can have such a narrow PDS.

[0055] Preferably, the mean flow pore size is between 10 and 200 micron, more preferably between 10 and 150 micron, even more preferably between 20 and 150 micron, and most preferably between 30 and 150 micron. For example, the mean flow pore size is between 30 and 120 micron or between 30 and 100 micron.

[0056] In an exemplary embodiment, the absorbent article comprises a top core wrap sheet arranged between the capillary acceleration sheet and the absorbent material, and the capillary acceleration sheet is sealed to the top core wrap sheet according to the sealing pattern, and optionally also to the first nonwoven through the top core wrap sheet.

[0057] Preferably, the sealing is realized by heat and / or pressure and / or ultrasonic energy. Preferably, the sealing is done by pressing one or more sealing bars against one or more zones overlapping with the one or more channels, said sealing bars being provided with protrusions according to the sealing pattern.

[0058] In an exemplary embodiment, the capillary acceleration sheet consists of a spunbond nonwoven fabric.In another exemplary embodiment, the capillary acceleration sheet consists of a spunbond meltblown nonwoven fabric or a spunbond-meltblown-spunbond nonwoven fabric.

[0059] Preferably, the capillary acceleration sheet has a basis weight between 5 and 55 g / m2, more preferably between 7 and 45 g / m2, even more preferably 8 and 30 g / m2, e.g. between 9 and 20 g / m2. Such basis weight, optionally in combination with the relatively fine fibres in the capillary acceleration sheet, provide for an adequate capillary suction force with low rewetting. More in particular, the liquid is sucked in very fast and is allowed to be distributed by the one or more channels and to be absorbed by the absorbent material reducing the chances of rewetting the top layer.

[0060] Where the application refers to basis weight, the basis weight may be measured using the ISO 9073-1 test method.

[0061] Preferably, the capillary acceleration sheet is a nonwoven comprising fibres having an average diameter between 10 and 35 micron, more preferably between 15 and 30 micron, even more preferably between 17 and 27 micron.

[0062] More in particular, the capillary acceleration sheet may have a fineness which results in a high capillary suction of liquid towards the absorbent material, where the liquid is further distributed through the at least one channel and absorbed by the absorbent material. Thus, the capillary acceleration sheet pulls liquid to the absorbent material in a very fast manner, resulting in a fast dryness at top sheet level.

[0063] In an exemplary embodiment, the capillary acceleration sheet has an average fineness which is between 2-6 dtex, i.e. between 1.8 and 5.4 den. It is noted that instead of or in addition to defining the average diameter of the capillary acceleration sheet, this sheet may also be defined using a fineness value, such as a dtex value or a den value. A den value may be determined using test method ASTM 1577.

[0064] Preferably, the capillary acceleration sheet is attached to the first nonwoven at least in a portion of the one or more channels. The attachment may be a continuous or discontinuous attachment. For example, the capillary acceleration sheet may be attached to the first nonwoven along a major portion of the one or more channels, with one or more unattached portions being present between attached portions. The one or more channels may comprise one or more permanent attachment portions which remain attached after wetting and / or one or more semi-permanent attachment portions which detachafter wetting and / or one or more unattached portions. An unattached portion or a semi-permanent attachment portion allows for an increased swelling of the absorbent material after the one or more channels have fulfilled their function of distributing the liquid, as wet absorbent material is allowed to extend / swell into the channel area in case of an unattached or detached portion.

[0065] More preferably, no additional sheet is present between the superabsorbent particles and the capillary acceleration sheet. In such an embodiment, the absorbent core can thus be formed by the bottom distribution assembly, the capillary acceleration sheet, and the absorbent material included between the capillary acceleration sheet and the bottom distribution assembly.

[0066] Preferably, the absorbent material extends over a surface area of the bottom distribution assembly, and the capillary acceleration sheet extends over the full surface area of the absorbent material. The capillary acceleration sheet may be attached along a periphery to the bottom distribution assembly. Thus the capillary acceleration sheet may fulfil the role of top core wrap sheet whilst at the same time providing a capillary structure configured for ensuring a fast dryness of the topsheet.

[0067] Even more preferably, no additional sheet is present between the topsheet and the capillary acceleration sheet. Thus, the capillary acceleration sheet can also fulfil the role of acquiring and distributing the liquid, and does this by fast capillary suction.

[0068] According to another possible embodiment, the absorbent article further comprises a top core wrap sheet arranged between the capillary acceleration sheet and the absorbent material. The top core wrap sheet may then be attached to the bottom distribution assembly at least in a portion of the one or more channels, and the capillary acceleration sheet may be attached to the top core wrap sheet in at least a portion of the one or more channels. When such an embodiment is used, the capillary acceleration sheet may be smaller than the bottom distribution assembly, and may be present where liquid insult is to be expected. It is further noted that the top and bottom distribution assembly may be two separate sheets or one sheet wrapping the absorbent material of the absorbent core.

[0069] According to an exemplary embodiment, the capillary acceleration sheet is a nonwoven with polypropylene (PP) fibres. The advantage of PP is that it can be easily shaped.

[0070] According to an exemplary embodiment, the topsheet is an apertured topsheet having apertures with a surface area larger than 0.1 mm2, preferably larger than 0.5 mm2. This allows liquid to pass easily through the topsheet towards the capillary acceleration sheet. Especially for embodiments where thecapillary acceleration sheet forms a barrier for superabsorbent particles such an embodiment is advantageous.

[0071] Optionally, a bottom core wrap sheet may be arranged between the bottom distribution assembly and the absorbent material, but typically this is not preferred. Such bottom core wrap sheet may have a specific volume above 15 g / m2.

[0072] According to an exemplary embodiment, the capillary acceleration sheet comprises a blend of fibres having different diameters. Preferably, the fibres are intermingled, i.e. preferably the different fibres are not arranged in layers but mixed with each other to form the capillary acceleration sheet. Preferably, a blend of polypropylene (PP) fibres is used. However, it is also possible to use other single component or bi-component fibres, such as polyethylene (PE) fibres, polyethyleneterephthalate (PET) fibres, PE / PP bi-component fibres, PE / PLA bi-component fibres, etc. The fibres may be continuously crimped fibres.

[0073] According to an exemplary embodiment, the capillary acceleration sheet comprises a blend of first fibres having an average first diameter above 20 micron, preferably above 22 micron, more preferably above 24 micron, and second fibres having an average second diameter below 20 micron, preferably below 19 micron, more preferably below 18 micron. In that manner, the fine second fibres will contribute to the fast capillary suction whilst the coarser first fibres will ensure a good distribution of the liquid, also by mass flow. Preferably, the first fibres represent less than 50 weight% of the capillary acceleration sheet, more preferably less than 45 weight%, and the second fibres represent more than 50 weight% of the capillary acceleration sheet, more preferably more than 55 weight%. Such a distribution provides a good balance between suction and migration by capillary flow promoted by the finer second fibres and liquid distribution by mass flow promoted by the coarser first fibres.

[0074] According to an exemplary embodiment, the capillary acceleration sheet is a continuous filament web. The capillary acceleration sheet may be a spunbond nonwoven, a carded nonwoven, a spunlace nonwoven. The capillary acceleration sheet may be made by spunbonding, carding, or spunlacing (hydro-entangling), or a combination thereof. If the capillary acceleration sheet is a spunbond web, it may be a calandered (i.e. a point bonded) spunbond web, preferably with a bonding area between 10 and 30%.

[0075] According to an exemplary embodiment, the capillary acceleration sheet comprises a fraction of fibres having an average diameter which is at least 10% lower than an average diameter of the fibresof the liquid pervious topsheet, preferably at least 20% lower than an average diameter of the fibres of the liquid pervious topsheet. By having finer fibres in the capillary acceleration sheet than in the topsheet, the liquid will pass fast through the topsheet and the main capillary suction will take place in the capillary acceleration sheet. Preferably, the topsheet has a basis weight between 10 and 30 g / m2, preferably between 15 and 25 g / m2. Preferably, the fibres of the topsheet have an average fineness between 1-3 dtex. Preferably, the topsheet is any one of the following: a spunbond nonwoven, a through air bonded carded web (TABCW). Preferably, the through air bonded carded web comprises polyethylene / polypropylene bi-component staple fibres.

[0076] According to an exemplary embodiment, at least a portion of the topsheet is bonded to the capillary acceleration sheet, preferably at least in a portion of the one or more channels.

[0077] According to an exemplary embodiment, the capillary acceleration sheet extends over at least 15%, preferably at least 20%, more preferably at least 45% of an upper surface area of the bottom distribution assembly; and / or wherein he capillary acceleration sheet extends over at least 25%, preferably at least 30%, more preferably at least 35% of a length of the bottom distribution assembly; and / or wherein the capillary acceleration sheet extends over at least 25%, preferably at least 30%, more preferably at least 35% of a width of the bottom distribution assembly. As explained above, in a preferred embodiment, the capillary acceleration sheet may extend over the entire upper surface of the bottom distribution assembly and may fulfil the function of a top core wrap sheet.

[0078] According to an exemplary embodiment, the bottom distribution assembly has a first and second longitudinal edge and a first and second transverse edge and the one or more channels comprise at least one elongate channel extending from a crotch region in the direction of the first and / or second transverse edge. Such channels will allow a good liquid distribution by mass flow between the first and second transverse edge.

[0079] According to an exemplary embodiment, the one or more channels comprise one or more attachment zones where the capillary acceleration sheet and / or the top core wrap sheet, if present, is attached to the back core wrap sheet. Preferably, the one or more attachment zones are formed by any one of the following or a combination thereof: pressure bonding, thermal bonding, sonic bonding, chemical bonding, adhesive. According to an exemplary embodiment, the one or more channels comprise any one or more of the following: one or more permanent attachment zones, one or more semi-permanent attachment zones configured to release after having been in contact with liquid, for example after having been in contact with the liquid for a time period of less than 2 minutes, one or more unattached zones.According to an exemplary embodiment, a width of the one or more channels, seen in a transverse direction of the bottom distribution assembly, is at least 1 mm, preferably at least 2 mm, more preferably at least 3 mm, most preferably at least 4mm. In that manner, it can be ensured that a sufficient amount of liquid can be distributed and any leakage can be limited or avoided.

[0080] According to an exemplary embodiment, the one or more channels comprise a first channel and a second channel which extend next to each other and are each extending in the direction of a first and / or second transverse edge of the bottom distribution assembly. Preferably, the first and second channel are oriented substantially in a longitudinal direction of the bottom distribution assembly. Preferably, the capillary acceleration sheet at least partially covers the first and second channel. In that manner, the capillary acceleration sheet can suck liquid towards the two channels.

[0081] According to an exemplary embodiment, the distance between the first and the second channel is between 10 mm and 50 mm, preferably between 15 mm and 30 mm; and / or the length of the first and the second channel is larger than 60 mm, preferably larger than 70 mm. Such dimensions will typically result in a good distribution. The skilled person understands that the dimensions will be dependent on the size of the absorbent article, and thus one the size of the bottom distribution assembly.

[0082] According to an exemplary embodiment, the one or more channels further comprise a third and a fourth channel located at a distance of each other and at a distance of the first and second channel, said third and fourth channel each extending in the direction of the first and / or second transverse edge. Preferably, the capillary acceleration sheet at least partially covers the third and fourth channel. By adding such a third and fourth channel the distribution can be further enhanced. Preferably, the distance between the first and the second channel is different from the distance between the third and the fourth channel.

[0083] Preferably, the bottom distribution assembly has a front portion extending at one side of a transverse crotch line and a rear portion extending at the other side of the transverse crotch line; wherein the first and second channel extend at least in the front portion of the bottom distribution assembly; and wherein the third and fourth channel extend at least in the rear portion of the bottom distribution assembly. Preferably, the distance between the first and the second channel is smaller than the distance between the third and the fourth channel. Optionally, the first channel may be connected to the third channel through a first semi-permanent attachment zone and the second channel may beconnected to the fourth attachment zone through a second semi-permanent attachment zone, wherein the first, second, third and fourth channels are formed by permanent attachment zones.

[0084] According to an exemplary embodiment, the one or more channels comprise at least a first and a second attachment zone located a distance of each other, said first and second attachment zone each extending from a crotch region in the direction of a first and / or second transverse edge of the bottom distribution assembly.

[0085] According to an exemplary embodiment, a position and / or shape of the one or more channels is indicated by means of a distinguishable colour and / or coloured pattern, e.g. by a printed ink layer. For example, the distinguishable colour and / or coloured pattern may be provided on at least one of the topsheet, the capillary acceleration sheet, the backsheet and the bottom distribution assembly.

[0086] According to an exemplary embodiment, the one or more channels together extend over a channel length which is at least 20 %, preferably at least 30%, preferably at least 40%, more preferably at least 50% of a length of the bottom distribution assembly.

[0087] According to an exemplary embodiment, the one or more channels and the capillary acceleration sheet are arranged symmetrically with respect to a longitudinal centre line of the bottom distribution assembly.

[0088] Preferably, the absorbent material comprises cellulosic fluff pulp made up of cellulose fibres and the first superabsorbent particles. The fibres can be natural or synthetic. According to another exemplary embodiment, the absorbent material is substantially fluffless. Typically, absorbent material refers to a material that is applied in bulk, i.e. a 3D absorbent material, i.e. not as a sheet. In some embodiments, the absorbent material may comprise more than 20 weight% first superabsorbent particles or more than 40 weight% first superabsorbent particles or more than 60 weight% first superabsorbent particles, or more than 80 weight% first superabsorbent particles. The absorbent material may also be fluffless, i.e. with substantially without cellulose fibres.

[0089] In some embodiments, the topsheet may function as capillary acceleration sheet, and may be in direct contact with the absorbent material, i.e. no further sheet is present between the topsheet and the absorbent material. The topsheet may then have any one of the properties described above for the capillary acceleration sheet.According to another aspect there is provided a method for manufacturing an absorbent article, preferably an absorbent article according to any one of the embodiments above, comprising the steps of providing a liquid pervious topsheet and a liquid impervious backsheet; arranging an absorbent material comprising first superabsorbent particles, between a bottom distribution assembly, on one side, and a top core wrap sheet and / or a capillary acceleration sheet, on the other side, such that one or more channels are formed, wherein less absorbent material per surface area is present in the one or more channels compared to areas around the one or more channels, wherein preferably substantially no absorbent material is present in the one or more channels; and arranging the liquid pervious topsheet at the side of top core wrap sheet and / or the capillary acceleration sheet and the liquid impervious backsheet at the side of the bottom distribution assembly, wherein the bottom distribution assembly comprises a first nonwoven, wherein the method further comprises arranging second superabsorbent particles in said first nonwoven.

[0090] Preferably, the first nonwoven is arranged in contact with the absorbent material.

[0091] Preferably, the first nonwoven is attached to the top core wrap sheet and / or the capillary acceleration sheet at least in a portion of the one or more channels, e.g. by gluing and / or sealing.

[0092] Preferably, the arranging of the absorbent material comprises the steps of guiding a first sheet material along a rotating member, wherein a surface of said rotating member is provided with a pattern with suction zones and non-suction zones; wherein said non-suction zones comprise one or more channel zones; applying an absorbent material on a first sheet material on the rotating member such that the suction zones are covered with absorbent material and substantially no absorbent material is present on the non-suction zones; and applying a second sheet material on top of the absorbent material on the first sheet material; and at least partially attaching said first sheet material to said second sheet material in the areas where substantially no absorbent material is present, such that one or more channels are formed. One of said first and second sheet material is a material for forming the capillary acceleration sheet and / or the top core wrap sheet and / or the topsheet, and the other one is a material for forming the first nonwoven or the bottom distribution assembly.

[0093] Preferably, the attaching is done by applying pressure and / or heat and / or ultrasonic energy on the first nonwoven or bottom distribution assembly and on at least one of the capillary acceleration sheet material and the top core wrap sheet material and the topsheet (depending on which one is present) in the areas where substantially no absorbent material is present. For example, a sealing pattern as described above may be used for the attaching. Optionally the sealing with a sealing pattern may be combined with applying an adhesive between the capillary acceleration sheet material and / or topcore wrap sheet, on the one hand, and the bottom layer or bottom distribution assembly on the other hand.

[0094] Any of the features described above in connection with the absorbent article are also applicable for embodiments of the method.

[0095] Preferably, the absorbent article is a disposable personal care article such as a diaper, a baby pant, an adult incontinent garment.

[0096] Centrifuge Retention Capacity Test (CRC)

[0097] The CRC of super absorbent particles may be measured using the Centrifuge Retention Capacity Test (CRC).

[0098] The CRC Test measures the ability of the superabsorbent polymer to retain liquid therein after being saturated and subjected to centrifugation under controlled conditions. The resultant retention capacity is stated as grams of liquid retained per gram weight of the sample, (g / g).

[0099] The CRC may be determined in accordance with ERT 441.2-02, which is incorporated by reference, “ERT” representing “EDANA recommended Test” and “EDANA” representing European Disposables and Nonwovens Association or as follows.

[0100] The CRC is measured by placing about 0.16 grams of the pre-screened superabsorbent polymer sample into a water-permeable bag that will contain the sample while allowing a test solution (0.9 weight percent sodium chloride in distilled water) to be freely absorbed by the sample. A heat-sealable tea bag material, such as that available from Dexter Corporation (having a place of business in Windsor Locks, Conn., U.S.A.) as model designation 1234T heat sealable filter paper works well for most applications. The bag is formed by folding a 5-inch by 3-inch sample of the bag material in half and heat-sealing two of the open edges to form a 2.5-inch by 3-inch rectangular pouch. The heat seals are about 0.25 inches inside the edge of the material. After the sample is placed in the pouch, the remaining open edge of the pouch is also heat-sealed. Empty bags are also made to serve as controls. Three samples are prepared for each super absorbent polymer composition to be tested. The sealed bags are submerged in a pan containing the test solution at an assigned testing temperature, making sure that the bags are held down until they are completely wetted. After wetting, the samples remain in the solution for an assigned period of testing time, at which time they are removed from the solution and temporarily laid on a non-absorbent flat surface.

[0101] The wet bags are then placed into the basket wherein the wet bags are separated from each other and are placed at the outer circumferential edge of the basket, wherein the basket is of a suitable centrifuge capable of subjecting the samples to a g-force of about 350. One suitable centrifuge is aCLAY ADAMS DYNAC II, model #0103, having a water collection basket, a digital rpm gauge, and a machined drainage basket adapted to hold and drain the flat bag samples. Where multiple samples are centrifuged, the samples are placed in opposing positions within the centrifuge to balance the basket when spinning. The bags (including the wet, empty bags) are centrifuged at about 1,600 rpm (e.g., to achieve a target g-force of about 350 g force with a variance from about 240 to about 360 g force), for 3 minutes. G force is defined as an unit of inertial force on a body that is subjected to rapid acceleration or gravity, equal to 32 ft / sec2at sea level. The bags are removed and weighed, with the empty bags (controls) being weighed first, followed by the bags containing the superabsorbent polymer composition samples. The amount of solution retained by the superabsorbent polymer sample, taking into account the solution retained by the bag itself, is the centrifuge retention capacity (CRC) of the superabsorbent polymer, expressed as grams of fluid per gram of superabsorbent polymer. More particularly, the retention capacity is determined by the following equation: CRC=[sample bag after centrifuge -empty bag after centrifuge -dry sample weight] / dry sample weight

[0102] The three samples are tested, and the results are averaged to determine the CRC of the superabsorbent polymer composition.

[0103] Vortex Time measurement method

[0104] The vortex may be measured using the following method. The vortex test measures the amount of time in seconds required for 2 grams of a superabsorbent material to close a vortex created by stirring 50 milliliters of saline solution at 600 revolutions per minute on a magnetic stir plate. The time it takes for the vortex to close is an indication of the free swell absorbing rate of the superabsorbent material.

[0105] Equipment and Materials

[0106] 1. Schott Duran 100 ml Beaker and 50 ml graduated cylinder.

[0107] 2. Programmable magnetic stir plate, capable of providing 600 revolutions per minute (such as that commercially available from PMC Industries, under the trade designation Dataplate® Model #721).

[0108] 3. Magnetic stir bar without rings, 7.9 millimeters- times- 32 millimeters, Teflon® covered (such as that commercially available from Baxter Diagnostics, under the trade designation S / PRIM. brand single pack round stirring bars with removable pivot ring).

[0109] 4. Stopwatch

[0110] 5. Balance, accurate to + / -0.01 g

[0111] 6. Saline solution, 0.87 w / w % Blood Bank Saline available from Baxter Diagnostics (considered, for the purposes of this application to be the equivalent of 0.9 wt. % saline

[0112] 7. Weighing paper8. Room with standard condition atmosphere: Temp=23° C. + / -1° C. and Relative Humidity=50% + / -2%.

[0113] Test Procedure

[0114] 1. Measure 50ml + / -0.01 ml of saline solution into the 100 ml beaker.

[0115] 2. Place the magnetic stir bar into the beaker.

[0116] 3. Program the magnetic stir plate to 600 revolutions per minute.

[0117] 4. Place the beaker on the center of the magnetic stir plate such that the magnetic stir bar is activated. The bottom of the vortex should be near the top of the stir bar.

[0118] 5. Weigh out 2 g + / -0.01 g of the superabsorbent material to be tested on weighing paper. NOTE: The superabsorbent material is tested as received (i.e. as it would go into an absorbent composite such as those described herein). No screening to a specific particle size is done, though the particle size is known to have an effect on this test.

[0119] 6. While the saline solution is being stirred, quickly pour the superabsorbent material to be tested into the saline solution and start the stopwatch. The superabsorbent material to be tested should be added to the saline solution between the center of the vortex and the side of the beaker.

[0120] 7. Stop the stopwatch when the surface of the saline solution becomes flat and record the time. 8. The time, recorded in seconds, is reported as the Vortex Time. Tea Bag Retention (TB Retention)

[0121] Measurement test for Absorption Against Pressure (AAP)

[0122] The Absorption Against Pressure (AAP) of the superabsorbent particles may be measured according to EDANA test method No. NWSP 242.0. R2 (15) (ISO 17190-7:2001) "Polyacrylate Superabsorbent Powders - Gravimetric Determination of Absorption Against Pressure", at 4.8 kPa (about 0.7 psi).

[0123] BRIEF DESCRIPTION OF FIGURES

[0124] The accompanying drawings are used to illustrate presently preferred non-limiting exemplary embodiments of devices of the present invention. The above and other advantages of the features and objects of the invention will become more apparent and the invention will be better understood from the following detailed description when read in conjunction with the accompanying drawings, in which:

[0125] FIGS. 1A to 1C are schematic cross-sections of an exemplary embodiments of an absorbent core with a bottom distribution assembly comprising a first nonwoven comprising second superabsorbent particles and a second non wo ven which forms a barrier;

[0126] FIG. ID is a schematic top view of the embodiments of FIGS. 1 A to 1C;FIG. IE is a schematic cross-sections of an exemplary embodiments of an absorbent article comprising the absorbent core of FIG. 1 A;

[0127] FIGS. 2A to 2B are schematic cross-sections of an exemplary embodiments of an absorbent core with a bottom distribution assembly comprising a first, a second and a third nonwoven;

[0128] FIGS. 3A to 3C are schematic cross-sections of exemplary embodiments of an absorbent core with a bottom distribution assembly comprising a first nonwoven comprising second superabsorbent particles and a second nonwoven comprising third superabsorbent particles;

[0129] FIGS. 3D and 3E are schematic cross-sections of exemplary embodiments of an absorbent core with a bottom distribution assembly comprising a first nonwoven comprising second superabsorbent particles and an additional non wo ven between the absorbent material and the first non wo ven; FIG. 4 is a schematic cross-section of an exemplary embodiment of an absorbent core with a bottom distribution assembly comprising a first, a second and a third nonwoven;

[0130] FIG. 5 A, 5B, 6A, 6B and 7 illustrate schematically exemplary embodiments of a method and apparatus for manufacturing an absorbent core;

[0131] FIGS. 8A to 8H are schematic top plan views of exemplary embodiments of a diaper;

[0132] FIG. 9 is a perspective view of an exemplary embodiment of a diaper in the wetted state;

[0133] FIGS. 10A-E illustrate an example of a set of sealing bars having a sealing pattern.

[0134] DESCRIPTION OF EMBODIMENTS

[0135] FIGS. 1A to IE

[0136] FIG. 1A to ID illustrate schematically three exemplary embodiments of an absorbent core which is intended to be included between a liquid pervious topsheet (not shown) and a liquid impervious backsheet (not shown) to form an absorbent article, in a manner known in the art. Preferably, the absorbent article is a disposable personal care article such as a diaper, a baby pant, an adult incontinent garment.

[0137] The absorbent core comprises a top core wrap sheet 110, absorbent material 130 and a bottom distribution assembly 120. The absorbent material 130 is positioned between the top core wrap sheet 110 and the bottom distribution assembly 120. The absorbent material 130 comprises cellulosic fluff pulp 131 and first superabsorbent particles 132 and is arranged such that a channel 160 is formed. In the illustrated examples one channel 160 is shown, but the skilled person understands that multiple channels may be provided in a manner known in the art. In the channel 160 less absorbent material per surface area is present compared to an area surrounding the channel 160, and preferably substantially no absorbent material is present in the channel 160. The bottom distribution assembly120 comprises a first nonwoven 121 and a second nonwoven 122. The first nonwoven 121 comprises second superabsorbent particles 142. Preferably, substantially no second superabsorbent particles 142 are present in the channel 160. The first nonwoven 121 is in direct contact with the absorbent material 130. The second nonwoven 122 is inserted between the first nonwoven 121 and the backsheet (not shown). By including second absorbent particles in the first non wo ven an additional storage reservoir is provided whilst the first nonwoven also fulfills a distribution function. This will allow to reduce the amount of absorbent material 130. Further, non wo ven 122 will improve the softness of the backside of the diaper.

[0138] Although the first and second superabsorbent particles 132, 142 may be the same, it is preferred that the one or more physical and / or chemical properties of the first superabsorbent particles 132 and second superabsorbent particles 142 are different, wherein more preferably the chemical properties are different. This allows to optimize the storage and distribution properties in the first nonwoven and to provide a good fit between the first non wo ven and the second superabsorbent particles 142.

[0139] The following parameters of the first and second superabsorbent particles 132, 142 may be considered to optimize the behavior of the absorbent core: the centrifuge retention capacity, CRC, the vortex and the absorption against pressure, AAP.

[0140] Assuming the first absorbent particles 132 have properties CRC1, vortex vl and AAP1 and the second absorbent particles 132 have properties CRC2, vortex v2 and AAP2, then preferably any one or more of the following conditions is fulfilled:

[0141] difference between CRC1 and CRC2 at least 2g / g, more preferably at least 3 g / g even more preferably at least 4g / g;

[0142] difference between vl and v2 is at least 10s, more preferably at least 15s, even more preferably at least 20s;

[0143] difference between AAP1 and AAP2 is at least 2g / g, more preferably at least 3 g / g, measured at 4.8 kPa;

[0144] CRC1 and CRC 2 between 25 and 50 g / g;

[0145] vl and v2 between 25 and 80 s;

[0146] AAP1 and AAP2 between 15 and 30 g / g.

[0147] In an advantageous embodiment, any one or more, preferably all of the following conditions is fulfilled:

[0148] CRC1 < CRC2;

[0149] vl < v2;- AAP1 > AAP2;

[0150] CRC1 between 25 and 40 g / g and CRC 2 between 35 and 50 g / g;

[0151] vl between 25 and 50 s and v2 between 35 and 80 s;

[0152] AAP1 between 20 and 30 g / g and AAP2 between 15 and 25 g / g.

[0153] Further, the difference criteria mentioned above may also be fulfilled in such an embodiment.

[0154] Preferably, an amount (expressed in g) of the first superabsorbent particles 132 in the absorbent material 130 is higher than an amount of the second superabsorbent particles 142 in the first non wo ven 121. Preferably, at least 1 g of the second superabsorbent particles 142 is included in the first nonwoven 121, more preferably at least 2g. In exemplary embodiments, the following amounts may be used:

[0155] absorbent material 130: between 2 and 6g cellulosic fluff pulp and between 10 and 14g first superabsorbent polymer particles 132; first nonwoven 121: between 0.5 and 5g second superabsorbent polymer particles 142.

[0156] absorbent material 130: between 1 and 5g cellulosic fluff pulp and between 5 and 10g first superabsorbent polymer particles 132; first nonwoven 121 between 3 and 7g second superabsorbent polymer particles 142;

[0157] an amount per surface area of the cellulosic fluff pulp in the absorbent material 130 is below 350 g / m2, preferably below 300 g / m2, more preferably below 250 g / m2, even more preferably below 200 g / m2, e.g. between 50 g / m2 and 180 g / m2;

[0158] an amount per surface area of the first superabsorbent particles 132 in the absorbent material 130 is between 100 g / m2 and 350 g / m2;

[0159] an amount of the second superabsorbent particles 142 in the first non woven 121 is above 15 g / m2, preferably between 20 g / m2 and 200 g / m2.

[0160] Preferably, the first nonwoven 121 is any one of the following: a carded through-air-bonded nonwoven, a spunlace nonwoven. Preferably, the first nonwoven 121 has a basis weight between 15 and 150 g / m2, more preferably between 30 and 85 g / m2, even more preferably between 35 and 80 g / m2.

[0161] The second non wo ven 122 is preferably configured to form a barrier for the second superabsorbent particles 142. The second non wo ven 122 may comprise for example a spunbond layer and / or a meltblown layer. Also, the second nonwoven may be a carded thermobonded nonwoven. It may be for example a PP spunbond nonwoven or an SMS or SMMS nonwoven or a PP carded thermobonded nonwoven. Preferably, the second nonwoven has a basis weight between 6 and 60 g / m2, more preferably between 8 and 40 g / m2.Preferably, the second non wo ven 122 has a second average density d2 which is higher than a first average density dl of the first non wo ven 121, wherein a difference between dl and d2 is higher than 20 kg / m3, preferably higher than 30 kg / m3 more preferably higher than 40 kg / m3, even more preferably between 50 and 150 kg / m3, most preferably between 60 and 140 kg / m3. For example, the first non wo ven may have an average density between 20 and 400 kg / m3, preferably between 20 and 300 kg / m3, more preferably between 20 and 250 kg / m3 and the second non wo ven 122 may have an average density between 50 and 400 kg / m3.

[0162] Optionally an additional capillary acceleration sheet (not shown) may be inserted between the top core wrap sheet 110 and the topsheet.

[0163] In the embodiment of FIG. 1A, the first non wo ven 121 and the second non wo ven 122 are sealed to the top core wrap sheet 110 at least in a portion of channel 160. In the embodiment of FIG. IB, only the first non wo ven 121 is sealed to the top core wrap sheet 110 at least in a portion of the channel 160, and the second non wo ven 122 is not sealed in the channel 160. The sealing may be done in accordance with a sealing pattern. Preferably, the sealing is realized by heat and / or pressure and / or ultrasonic energy. Preferably, the sealing pattern covers less than 70%, preferably less than 60%, more preferably less than 50%, even more preferably between 1 and 40% of the surface area of the one or more channels 160.

[0164] In the embodiment of FIG. 1C, the first non wo ven 121 and optionally the second non wo ven 122 are glued to the top core wrap sheet 110 at least in a portion of the channel 160.

[0165] Also, in the embodiments of FIG. 1A to 1C, the first nonwoven 121, and optionally also the second non wo ven 122, are attached along a periphery to the top core wrap sheet 110.

[0166] FIG. ID shows a top view which is representative for all three embodiments of FIGS. 1 A to 1C.

[0167] FIG. IE shows an absorbent article comprising the absorbent core of FIG. 1 A but this could also be the absorbent core of FIG. IB or FIG. 1C. The absorbent article comprises a liquid pervious topsheet 300, a liquid impervious backsheet 200 and the absorbent core of FIG. 1A inserted between the topsheet 300 and the backsheet 200. Optionally, a capillary acceleration sheet 400 or an acquisition distribution layer 400 may be inserted between the topsheet 300 and the backsheet 200. The capillary acceleration sheet 400 may have any one of the properties described above in the summary.FIGS. 2A to 2B

[0168] FIG. 2A illustrates an embodiment similar to the embodiment of FIG. 1C but further comprising a third nonwoven 123 below the second nonwoven. In the absorbent article, the third nonwoven is intended to be attached to the backsheet (not shown). The third non woven 123 may have an additional wicking function. For the other components reference is made to the description above of FIG. 1C.

[0169] FIG. 2B illustrates an embodiment similar to the embodiment of FIG. 1A but further comprising a third nonwoven 123 below the second nonwoven. In the absorbent article, the third nonwoven is intended to be attached to the backsheet (not shown). The third non woven 123 may have an additional wicking function. For the other components reference is made to the description above of FIG. 1A.

[0170] FIGS. 3A to 3E

[0171] FIGS. 3A and 3B illustrate an embodiment similar to the embodiment of FIGS. 1C and IB, respectively, wherein the bottom distribution assembly comprises a second nonwoven 122’ arranged between the backsheet and the first nonwoven and the second nonwoven 122’ comprises third superabsorbent particles 152. Preferably, the one or more physical and / or chemical properties of the second superabsorbent particles 142 and third superabsorbent particles 152 are different, more preferably the chemical properties are different. Typically, the centrifuge retention capacity, CRC, and / or the vortex and / or the AAP of the second superabsorbent particles 142 and the centrifuge retention capacity, CRC, and / or the vortex and / or the AAP of the third superabsorbent particles 152 are different. Preferably, an amount (expressed in g) of the second superabsorbent particles 142 in the first non wo ven 121 is different from an amount of the third superabsorbent particles 152 in the second nonwoven 122’. Preferably, the second nonwoven 122’ has a basis weight between 15 and 150 g / m2, preferably between 20 and 130 g / m2. For the other components reference is made to the description above of FIG. 1C.

[0172] It is further noted that preferably, substantially no second superabsorbent particles 142 are present in the channel area 160, while the second superabsorbent particles may be present in the channel area 160. Especially if the channel area 160 needs to be sealed, it is preferred that no superabsorbent particles are present in the layers to be sealed.In the embodiment of FIG. 3 A, the first non wo ven 121 and optionally the second non wo ven 122 are glued to the top core wrap sheet 110 at least in a portion of the channel 160. In the embodiment of FIG. 3B, the first non wo ven 121 is sealed to the top core wrap sheet 110 at least in a portion of the channel 160. The sealing may be done in accordance with a sealing pattern. Preferably, the sealing is realized by heat and / or pressure and / or ultrasonic energy. Preferably, the sealing pattern covers less than 70%, preferably less than 60%, more preferably less than 50%, even more preferably between 1 and 40% of the surface area of the one or more channels 160.

[0173] The embodiment of FIG. 3C is similar to the embodiment of FIG. 2B but the amount (in g) of the second superabsorbent particles 142 is lower than the amount of the third superabsorbent particles 152.

[0174] The embodiment of FIG. 3D is similar to the embodiment of FIG. IB but the bottom distribution assembly further comprises an additional layer 124 between the absorbent material 130 and the first non wo ven 121. The additional non wo ven 124 may function as a wicking layer. The embodiment of FIG. 3E is similar to the embodiment of FIG. 3D but the top core wrap sheet 110 is sealed to the first non wo ven 121.

[0175] FIG. 4

[0176] The embodiment of FIG. 4 is similar to the embodiment of FIG. 2A but further comprises a third non wo ven 123 below the second non wo ven 122’, wherein the third non wo ven functions as a barrier layer for the third superabsorbent particle 152.

[0177] In the embodiments described above, the absorbent core comprises a top core wrap sheet 110. A top core wrap sheet 110 preferably has a basis weight between 5 and 15 gsm and preferably comprises a spunbond and a meltblown layer.

[0178] This top core wrap sheet 110 may be replaced in all embodiments with a capillary acceleration sheet 400 having the characteristics described in the summary. In such an embodiment, the layer 400 may be omitted in FIG. IE.

[0179] FIGS. 5 A, 5B, 6A, 6B and 7

[0180] FIG. 5A illustrates a first embodiment of a method for manufacturing an absorbent core for an absorbent article, preferably an absorbent article according to any one of the embodiments describedabove. The method comprises the step of arranging an absorbent material 130 comprising first superabsorbent particles 132, between a bottom distribution assembly 120, on one side, and a top core wrap sheet 110 and / or a capillary acceleration sheet 400, on the other side, such that one or more channels 160, 160’ are formed, wherein less absorbent material per surface area is present in the one or more channels 160, 160’ compared to areas around the one or more channels 160, 160’, wherein preferably substantially no absorbent material is present in the one or more channels 160, 160’.

[0181] In the embodiment of FIG. 5 A the top core wrap sheet 110 and / or a capillary acceleration sheet 400 are provided on a drum 10, and the absorbent material 130 is arranged whilst the embodiment the top core wrap sheet 110 and / or a capillary acceleration sheet 400 is on the drum 10, whereupon the bottom distribution assembly 120 is arranged over the absorbent material 130.

[0182] The bottom distribution assembly 120 comprises a first non wo ven 121, and the method further comprises arranging second superabsorbent particles 142 on said first nonwoven 121 using a hopper means 42. To promote the incorporation of the second superabsorbent particles 142 in the first non wo ven 121, the first non wo ven may be heated and / or vibrated to facilitate the incorporation of the superabsorbent particles 142 in the first nonwoven 121, for example using a method as described in the EP 3 466 387 Bl in the name of the Applicant, which is incorporated herein by reference. Although not illustrated, the second superabsorbent particles 142 may be arranged in accordance with a pattern, for example a pattern matching the pattern of the absorbent material 130. This may be achieved in a similar manner as for the absorbent material 130, using suction and non-suction zones.

[0183] In a non-illustrated step, there is arranged a liquid-pervious topsheet at the side of top core wrap sheet 110 and / or the capillary acceleration sheet 400 and a liquid impervious backsheet at the side of the bottom distribution assembly 120, to produce the absorbent article. The skilled person understand that in embodiments with a capillary acceleration sheet 400, the capillary acceleration sheet 400 may be first laminated, e.g. adhered, to a topsheet material (not shown), and the combination of the capillary acceleration sheet 400 and the topsheet may then be arranged against the top core wrap sheet 110, wherein optionally the capillary acceleration sheet 400 may be glued to the top core wrap sheet 110.

[0184] In the embodiment of FIG. 5 A, the first non wo ven 121 is arranged in contact with the absorbent material 130, wherein optionally adhesive may be inserted between the first non wo ven 121 and the absorbent material 130, see adhesive application means 60.As illustrated in FIG. 5A, an exemplary apparatus for performing such method comprises a rotating member 10, typically a drum, for supporting a first web, here a first web for producing the top core wrap sheet 110 and / or the capillary acceleration sheet 400 of the absorbent core, but in other embodiments this could be bottom distribution assembly, see also FIG. 5B. The first web may be guided to the drum 10 via a guide roller 5. The apparatus further comprises a hopper means 40 for providing the absorbent material 130 comprising the first superabsorbent particles 132 and optionally cellulosic fluff pulp 131, on said first web, in subsequent absorbent material areas to form subsequent absorbent cores. The apparatus further comprises a guide means 20 for guiding a second web, here a second web for forming the bottom distribution assembly 120, over said first web, a channel sealing and / or pressing means 30, 30’, typically two rollers, configured for sealing and / or pressing the second web to the first web in one or more bonding zones intended to form the one or more channels 160, 160’. Preferably, the sealing or embossing means 30, 30’ comprises a sealing roller 30’ configured to perform thermo-sealing. The sealing roller 30’ may be provided with channel sealing bars 31, 32 for the intended bonding areas. Thus, in such an embodiment, the separate channel sealing means 560, 560’ may be omitted.

[0185] Preferably, the rotating member 10 is provided with suction zones 13, 13’ configured to arrange the absorbent material 130 such that at least one channel 160, 160’ is formed, wherein less absorbent material per surface area is present in the at least one channel 160, 160’ compared to areas around the at least one channel 160, 160’, wherein preferably substantially no absorbent material is present in the at least one channel 160, 160’. To achieve this, one or more inserts 11, 12; 11’, 12’ may be provided to the rotating member 10 so as to block the suction in the one or more channel areas and so as to protrude outwardly relative to the surrounding surface where the absorbent material 130 is deposited.

[0186] Optionally, the apparatus further comprises a folding unit (not shown) configured for generating a C-fold wrapping around the absorbent material 130. Such folding units are known to the skilled person and will generate a C-wrap, by folding longitudinal edges of the first web around the second web.

[0187] Preferably, the surface of the rotating member 10 is provided with a pattern with suction zones 13 and non-suction zones 11 , 12, 15. The first web is shown in a transparent manner to reveal the suction zones 13 and non-suction zones 11, 12, 15 of the rotating member 10. The suction zones 13 may be provided with holes, and the non-suction zones 11, 12, 15 are formed of closed material. For example, the non-suction zones 11, 12, may be provided through channel inserts. The channel inserts11, 12 may have a trapezoidal cross section. The number of inserts 11, 12 depends on the number of channels to be realized. The inserts 11, 12 may be fixed e.g. with screws on the rotating member 10. Further a peripheral frame (not shown) may be provided around the absorbent material area also covering the non-suction zone 15 where the transverse bonding zone is intended to be located. At an inner area of the rotating member 10 a vacuum is applied, see VACUUM 1. The non-suction zones 11, 12 preferably comprise at least a first elongate zone and a second elongate zone extending in a circumferential direction of the rotating member 10, so as to form two channels 160, 160’. Absorbent material 130 is applied via hopper 40 on the first web on the rotating member 10 such that the suction zones 13 are covered with absorbent material and substantially no absorbent material is present on the non-suction zones 11, 12, 15. In a further step a second web is applied on top of the absorbent material 130 on the first web, e.g. using further rotating member 20. In a further step the first web is attached to the second web at least in the areas 11, 12, 15 where substantially no absorbent material is present, and such that one or more channels 160, 160’ and a transverse bonding zone are formed. The attaching may be done by applying pressure and / or heat and / or ultrasonic energy on the sandwich formed by the first web and the second web, especially in the one or more channels 160, 160’, e.g. by a rotating member 30 and / or opposite rotating member 30’, rotating member 30’ being provided with at least a first and a second seal rib or bar 31 , 32 dimensioned for applying pressure and / or heat in order to create the one or more channels 160, 160’.

[0188] The apparatus further comprises an optional adhesive applications means 60 for applying adhesive on the second web and an optional adhesive applications means 80 for applying adhesive on the first web. The adhesive may be applied for example as described in patent EP 3 453 368 Bl in the name of the applicant, which is included herein by reference.

[0189] FIG. 5B illustrates a similar embodiment of a method and apparatus for manufacturing an absorbent core for an absorbent article, preferably an absorbent article according to any one of the embodiments described above. The method comprises the step of arranging an absorbent material 130 comprising first superabsorbent particles 132, between a bottom distribution assembly 120, on one side, and a top core wrap sheet 110 and / or a capillary acceleration sheet 400, on the other side, such that one or more channels 160, 160’ are formed, wherein less absorbent material per surface area is present in the one or more channels 160, 160’ compared to areas around the one or more channels 160, 160’, wherein preferably substantially no absorbent material is present in the one or more channels 160, 160’.

[0190] In the embodiment of FIG. 5B, contrary to the embodiment of FIG. 5 A, a first web 121 for forming bottom distribution assembly 120 is provided on the rotating member 10, and a second web forforming the top core wrap sheet 110 and / or the capillary acceleration sheet 400 is arranged afterwords on the absorbent material 130. The second superabsorbent particles 142 are first applied on the first non wo ven 121 so as to incorporate the second superabsorbent particles 142 in the first non wo ven web 121 and next the absorbent material 130 comprising the first superabsorbent particles 132 is applied via hopper means 40. It is noted that hopper means 40 is schematically shown as one combined hopper means with a separation wall between a compartment for the second superabsorbent particles 142 and the absorbent material 130, but this could also be embodied using two separate hopper means. Also, the optional adhesive application means 80 could be inserted between a first hopper means for the application of the second superabsorbent particles 142 and a second hopper means for the application of the absorbent material 130.

[0191] The method comprises arranging second superabsorbent particles 142 on said first non wo ven 121. The second superabsorbent particles 142 are arranged in accordance with a pattern matching the pattern of the absorbent material 130. To promote the incorporation of the second superabsorbent particles 142 in the first non wo ven 121, the first nonwoven 121 may be heated and / or vibrated to facilitate the incorporation of the superabsorbent particles 142 in the first non wo ven 121, for example using a method as described in the EP 3 466 387 Bl in the name of the Applicant, which is incorporated herein by reference.

[0192] The other components are similar to the components explained for FIG. 5A and reference is made to the description above of FIG. 5A.

[0193] FIG. 6A illustrates a further embodiment which is similar to the embodiment of FIG. 5A with this difference that the bottom distribution assembly comprises a second nonwoven 122’ and that third superabsorbent particles 152 are included in the second non wo ven 122’ to produce an absorbent core as illustrated in FIG. 3A to 3C or FIG. 4. On the left of FIG. 6A it can be seen that third superabsorbent particles 152 are arranged on the second non wo ven 122’. Although not illustrated, the third superabsorbent particles 152 may be arranged in accordance with a pattern, for example a pattern matching the pattern of the absorbent material 130. However, it is also possible to use a different pattern, for example over substantially the entire surface of the absorbent core as illustrated in FIGS. 3 A to 3C or FIG. 4.

[0194] The apparatus further comprises an optional adhesive applications means 70 for applying adhesive on the second nonwoven 122’, an optional adhesive applications means 60 for applying adhesive on the first non wo ven 121 and an optional adhesive applications means 80 for applying adhesive on the first web for the top core wrap sheet 110 and / or the capillary acceleration sheet 400. The adhesive60, 80 may be applied for example as described in patent EP 3 453 368 Bl in the name of the applicant, which is included herein by reference.

[0195] The other components are similar to the components explained for FIG. 5A and reference is made to the description above of FIG. 5A.

[0196] FIG. 6B illustrates a further embodiment which is similar to the embodiment of FIG. 5B with this difference that the bottom distribution assembly comprises a second nonwoven 122’ and that third superabsorbent particles 152 are included in the second non wo ven 122’ to produce an absorbent core as illustrated in FIG. 3 A to 3C or FIG. 4. It can be seen that third superabsorbent particles 152 are arranged in the second non wo ven 122’, using hopper means 40 and suction zones 13, 13’ which suck the third superabsorbent particles 152 into the second non wo ven 122’ which is below the first non wo ven 121. Next, the second superabsorbent particles 142 are arranged and the second superabsorbent particles 142 are sucked into the first non wo ven layer 121. Finally, absorbent material 130 is arranged.

[0197] The second super absorbent particles 142 and the third superabsorbent particles 152 are arranged in accordance with a pattern matching the pattern of the absorbent material 130, using inserts 11, 12 as described in detail above for FIG. 5A. To promote the incorporation of the second and third superabsorbent particles 142, 152 in the first and second nonwoven 121, 122’, the first and second nonwoven 121, 122’ may be heated and / or vibrated to facilitate the incorporation of the superabsorbent particles 142, 152 in the first and second nonwoven 121, 122’, for example using a method as described in the EP 3 466 387 Bl in the name of the Applicant, which is incorporated herein by reference.

[0198] It is noted that hopper means 40 is schematically shown as one combined hopper means with a first separation wall between a compartment for the third superabsorbent particles 152 and a compartment for the second superabsorbent particles 142 and a second separation wall between a compartment for the second superabsorbent particles 142 and a compartment for the absorbent material 130, but this could also be embodied using three separate hopper means. Also, preferably, the optional adhesive application means 80 could be inserted between a first hopper means for the application of the second superabsorbent particles 142 and a second hopper means, downstream of the first hopper means, for the application of the absorbent material 130.

[0199] The other components are similar to the components explained for FIG. 5A and reference is made to the description above of FIG. 5A.FIG. 7 illustrates a further embodiment which is similar to the embodiment of FIG. 5B with this difference that the bottom distribution assembly comprises a second nonwoven 122’ and that third superabsorbent particles 152 are included in the second non wo ven 122’ to produce an absorbent core as illustrated in FIG. 3 A to 3C or FIG. 4. It can be seen that third superabsorbent particles 152 are arranged in the second nonwoven 122’, using hopper means 44 and a second drum 10’ having similar suction zones 13, 13’ as the drum 10, which suck the third superabsorbent particles 152 into the second nonwoven 122’. The second superabsorbent particles 142 are arranged via hopper means 40 and drum 10 as previously described, wherein the second superabsorbent particles 142 are sucked into the first non wo ven layer 121, and next absorbent material 130 is arranged on the first non woven 121 via hopper means 40.

[0200] The second super absorbent particles 142 and the third superabsorbent particles 152 are arranged in accordance with a pattern matching the pattern of the absorbent material 130, using inserts 11, 12 on drum 10 and 10’ as described in detail above for FIG. 5A. To promote the incorporation of the second and third superabsorbent particles 142, 152 in the first and second nonwoven 121, 122’, the first and second nonwoven 121, 122’ may be heated and / or vibrated to facilitate the incorporation of the superabsorbent particles 142, 152 in the first and second nonwoven 121, 122’, for example using a method as described in the EP 3 466 387 Bl in the name of the Applicant, which is incorporated herein by reference. The assembly comprising the absorbent material 130 and the second superabsorbent particles 142 between sheet 110 and / or 400 and sheet 121 can then be combined with the second non wo ven 122” comprising the third superabsorbent particles 152 to form the absorbent core.

[0201] It is noted that hopper means 40 is schematically shown as one combined hopper means with a separation wall between a compartment for the second superabsorbent particles 142 and a compartment for the absorbent material 130, but this could also be embodied using two separate hopper means. Also, preferably, the optional adhesive application means 80 could be inserted between a first hopper means for the application of the second superabsorbent particles 142 and a second hopper means, downstream of the first hopper means, for the application of the absorbent material 130.

[0202] The other components are similar to the components explained for FIG. 5A and reference is made to the description above of FIG. 5A.The first non wo ven 121, the second non wo ven 122’ (if present), the top core wrap sheet 110 (if present), the capillary acceleration sheet 400 (if present), may have any one of the features described above or described in the summary for those layers. Further nonwovens, such as nonwoven 123 (see for example FIG. 4) or non wo ven 124 (see for example FIG. 3E) may be added as will be understood by the person skilled in the art.

[0203] FIGS. 8A to 8H

[0204] Now a series of embodiments of channel and CAS arrangements will be illustrated with reference to FIGS. 8A to 8H for exemplary embodiments which comprise both a top core wrap sheet 100 and a capillary acceleration sheet (CAS) 400. Those embodiments may all have the features of FIG. 1 A to 4, with this difference that the one or more channels and the CAS 400 are arranged in a different manner.

[0205] FIG. 8A illustrates an exemplary embodiment of an absorbent article with an absorbent core 100 with a single central channel 180 extending in a longitudinal direction of the absorbent core 100. In FIG. 8A the CAS 400 is shown to extend over only a portion of the surface area of the absorbent core 100, but it will be understood that it can also extend over the entire surface area of the absorbent core 100.

[0206] Preferably, the channel 180 extends over at least 20% of the length of the absorbent core 100, more preferably at least 30%, even more preferably at least 40%. Preferably, the channel 180 extends, seen in the transverse direction of the absorbent core, over the transverse distance which is at least 1 mm, preferably at least 3 mm, more preferably at least 4 mm, even more preferably at least 5 mm, most preferably at least 6 mm. The length 180 of the channel may be larger than 30 mm, preferably larger than 40 mm, more preferably larger than 50 mm. In the channel 180 the CAS 400 may be attached to the top core wrap sheet through one or more permanent or semi-permanent attachment portions. The semi-permanent portions may be configured to release after having been in contact with liquid whilst said permanent portions may be configured not to release after having been in contact with liquid. It is noted that different types of semi-permanent attachment portions may be used in the same absorbent article so as to achieve a gradual loosening of the attachments upon wetting. The absorbent material in the absorbent core 100 preferably comprises cellulosic fluff pulp and / or superabsorbent particles. However, the absorbent material may be substantially fluffless.

[0207] Preferably, substantially no absorbent material is present in the channel 180. A position and / or shape of the channel 180 may be indicated by means of a distinguishable color and / or colored pattern. E.g.,a position and / or shape of the channel 180 may be indicated by means of a printed ink layer. The distinguishable color and / or colored pattern may be provided on at least one of the topsheet, the top core wrap sheet, the CAS 400, the backsheet and the bottom distribution assembly.

[0208] According to a preferred embodiment, outside of the channel 180 the absorbent core has a maximum thickness and the channel 180 extends through at least 90 % of the maximum thickness of the absorbent core, more preferably through substantially 100% of the thickness of the absorbent core 100 such that in the first and second attachment zone substantially no absorbent material is present.

[0209] FIG. 8B and FIG. 8C illustrate exemplary embodiments with two channels 140, 150. In FIG. 8B and FIG. 8C the CAS 400 is shown to extend over only a portion of the surface area of the absorbent core 100, but it will be understood that it can also extend over the entire surface area of the absorbent core 100.

[0210] The absorbent core 100 has a first and second longitudinal edge and a first and second transverse edge and the channels comprise 140, 150 are elongate channels extending from a crotch region in the direction of the first and second transverse edge. The channels 140, 150 may comprise one or more attachment zones where the CAS 400 and / or the top core wrap sheet is attached to the back core wrap sheet. Preferably the one or more attachment zones are formed by any one of the following or a combination thereof: pressure bonding, thermal bonding, sonic bonding, chemical bonding, adhesive. Preferably, a width of the channels 140, 150, seen in a transverse direction of the absorbent core 100, is at least 5 mm, preferably at least 6 mm, more preferably at least 8 mm, most preferably at least 9 mm, e.g. between 9 and 20 mm or between 10 and 20 mm or between 10 and 15 mm or between 12 and 15 mm. The channels 140, 150 may comprise any one or more of the following: one or more permanent attachment zones, one or more semi-permanent attachment zones configured to release after having been in contact with liquid, one or more unattached zones.

[0211] Preferably, each channel has a width measured in a transverse direction of the absorbent core, said width being at least 5% of the width of the absorbent core 100, preferably at least 7%, e.g. at least 10%, e.g. at least 15% or even at least 20%. For example, the channel width may be between 9 and 20 mm and the width of the absorbent material deposition area may be between 80 and 200 mm, e.g. between 90 and 150 mm. Preferably, the width of each channel is less than 30% of the width of the absorbent core, e.g. less than 25%. By having wider channels, the risk of getting fluff material in the one or more channels may be reduced.The channels 140, 150 extend next to each other and are each extending in the direction of a first and / or second transverse edge. Preferably, the CAS 400 at least partially covers both channels 140, 150. In FIG. 8B the CAS 400 partially covers the channels 140, 150, whilst in FIG. 8C the channels are fully covered. Preferably, the distance between the channels 140, 150 is between 10 mm and 50 mm, preferably between 15 mm and 30 mm; and the length of the first and the second channel is larger than 60 mm, preferably larger than 70 mm.

[0212] The absorbent core 100 has a front portion extending at one side of a transverse crotch line and a rear portion extending at the other side of the transverse crotch line. In FIG. 8B and FIG. 8C, the front portion corresponds with an upper portion of the absorbent core 100.

[0213] In FIG. 8B and FIG. 8C, the illustrated channels 140, 150 are straight channels but it will be understood that the channels may also be curved channels, wherein the distance between the channels increases toward the front transverse edge and / or towards the rear transverse edge of the absorbent core 100.

[0214] FIG. 8D illustrates an embodiment with four channels: a first channel 140, a second channel 150, a third channel 160, and a fourth channel 170. In FIG. 8D, the CAS 400 is shown to extend over only a portion of the surface area of the absorbent core 100, but it will be understood that it can also extend over the entire surface area of the absorbent core 100.

[0215] The third and fourth channel 160, 170 are located at a distance from each other and at a distance of the first and second channel 140, 150. As illustrated, the CAS 400 may cover all four channels 140, 150, 160, 170. Preferably, the distance between the first and the second channel 140, 150 is different from the distance between the third and the fourth channel 160, 170. Preferably, the first and second channel 140, 150 extend at least in the front portion 100a of the absorbent core 100, and the third and fourth channel 160, 170 extend at least in the rear portion 100b of the absorbent core 100, wherein preferably the distance between the first and the second channel 140, 150 is bigger than the distance between the third and the fourth channel 160, 170. Optionally, the first channel 140 is connected to the third channel 160 through a first semi-permanent attachment zone and the second channel 150 is connected to the fourth attachment zone 170 through a second semi-permanent attachment zone. Preferably, the first, second, third and fourth channels comprise permanent attachment zones.

[0216] Preferably, the first and second channel 140, 150 extend longitudinally between respective ends 141, 142, 151, 152, and the third and fourth channel 160, 170 extend longitudinally between respectiveends 161, 162, 171, 172. A first end 141 of the first channel 140 may be located at a distance x of a first end 161 of the third channel 160, with absorbent material extending between the ends 141 and 161. Similarly, a first end 151 of the second channel 150 may be located at a distance x of a first end 171 of the fourth channel 170, with absorbent material extending between the ends 151 and 171.

[0217] Optionally, aposition and / or shape of one or more channels 140, 150, 160, 170 is indicated by means of a distinguishable color and / or colored pattern, e.g. by a printed ink layer, wherein preferably the distinguishable color and / or colored pattern is provided on at least one of the topsheet, the CAS 400, the backsheet and the bottom distribution assembly. Preferably, the channels 140, 150, 160, 170 and the CAS 400 are arranged symmetrically with respect to a longitudinal center line of the absorbent core 100.

[0218] A first distance between the first and the second channel 140, 150 may be at least 5%, preferably at least 10% bigger, even more preferably at least 20% bigger than a second distance between the third and the fourth channel 160, 170. This difference may be optimized in function of the desired used. For example, for male persons the difference may be bigger.

[0219] Seen in a projection on the longitudinal direction of the absorbent core 100, the first and the second channel 140, 150 may extend over a length 11 which is less than the length 13 of the third and fourth channel 160, 170. To fit better to the body the third and fourth channel 160, 170 which are closer to each other may be longer to extend over a longer part of the crotch region, for example the third and fourth channel 160, 170 may extend both in the front and the rear portion 100a, 100b of the absorbent core 100. Preferably, the first and the second channel 140, 150 extend over a length 11 which is at least 5% less, more preferably at least 10% less than the length 13 of the third and fourth channel 160, 170. Preferably the first and the second channel 140, 150 extend over a length 11 which is at least 25%, more preferably at least 35%, even more preferably at least 45% of the length 13 of the third and fourth channel 160, 170.

[0220] FIG. 8E and 8F illustrate an absorbent article comprising an absorbent core 100 having a first and second longitudinal edge and a front and rear transverse edge. The absorbent core is provided with two interconnected elongate channels 140, 150 extending next to each other from a crotch region in the direction of the front and / or rear transverse edge and at least one connecting channel 1045, 1045’ connecting the first channel with the second channel. By providing a first and a second elongate channel which are interconnected by at least one connecting channel, upon wetting of the absorbent core, liquid can flow from the first elongate channel to the second elongate channel and vice versa, improving the liquid distribution, whereupon the liquid can be absorbed by the absorbent material.In FIG. 8E and 8F, the CAS 400 is shown to extend over only a portion of the surface area of the absorbent core 100, but it will be understood that it can also extend over the entire surface area of the absorbent core 100.

[0221] In FIG. 8E the at least one connecting channel comprises a rear connecting channel 1045 which connects a rear end portion of the first channel 140 to a corresponding rear end portion of the second channel 150. In FIG. 8F both a rear connecting channel 1045 and a front connecting channel 1045’ which connects a front end portion of the first channel to a corresponding front end portion of the second channel, are provided. In that manner a good distribution is obtained in the front portion and / or in the rear portion. Especially for a male person, it may be desirable to have a front connecting channel.

[0222] The absorbent core 100 has a transverse crotch line dividing the absorbent core in a front portion and a rear portion on either side of the transverse crotch line. Preferably, the front connecting channel is located in the front portion and / or the rear connecting channel is located in the rear portion.

[0223] Preferably, the absorbent core 100 is substantially symmetrical with respect to a longitudinal center axis. For example, the channel area 140, 150, 1045, 1045’ may be substantially V-shaped or U-shaped or O-shaped, wherein the V-shape or U-shape is arranged such that it is symmetrical with respect to the longitudinal center axis of the absorbent core.

[0224] In an exemplary embodiment, the first and second channels comprise permanent attachment zones which remain attached upon wetting, or semi-permanent attachment zones configured to release after having been in contact with liquid for a predetermined period of time, wherein said predetermined period of time is preferably smaller than 30 s. In a preferred embodiment the at least one connecting channel 1045, 1045’ comprises any one or more of: a permanent attachment portion which remains attached upon wetting, a semi-permanent attachment portion configured to release after having been in contact with liquid for a predetermined period of time, wherein said predetermined period of time is preferably smaller than 30s, and unattached portion. Attachment portion / zone refers to a portion / zone where the CAS 400 and / or the top core wrap sheet is attached to the bottom distribution assembly.

[0225] In an exemplary embodiment, the first channel and the second channel are substantially parallel and extend in a longitudinal direction of the absorbent core 100. In another embodiment, see FIG. 8E, the first and second channel 140, 150 may diverge in the direction of the front edge of the absorbent core 100.In an exemplary embodiment, the largest distance between the first and the second channel in the transverse direction is between 15 and 70% of the width of the absorbent core, more preferably between 20 and 50%; wherein preferably the largest distance between the first and the second channel in the transverse direction is between 10 mm and 100 mm, more preferably between 20 mm and 80 mm, even more preferably between 30 mm and 70 mm.

[0226] FIG. 8G illustrates an embodiment with an X-shaped channel area. In FIG. 8G, the CAS 400 is shown to extend over only a portion of the surface area of the absorbent core 100, but it will be understood that it can also extend over the entire surface area of the absorbent core 100.

[0227] The absorbent core 100 has a first and second longitudinal edge and a first and second transverse edge, and a longitudinal center line dividing the absorbent core in a first longitudinal portion and a second longitudinal portion on either side of the longitudinal center line, and a transverse crotch line dividing the absorbent core in a front portion and a rear portion on either side of the transverse crotch line. The absorbent core is provided with a plurality of channels 140, 150, 160, 170 comprising a first channel 140, 170 and second channel 150, 160 extending next to each other from a crotch region in the direction of the front and rear transverse edge. The first channel 140, 170 crosses the longitudinal center line in a first crossing point, from the first longitudinal portion to the second longitudinal portion; and the second elongate channel 150, 160 crosses the longitudinal center line in second crossing point, from the second longitudinal portion to the first longitudinal portion. The first and second crossing point may be the same point (as in FIG. 8G) or a different point, and may be located in the front portion or in the rear portion or on the transverse crotch line between connecting the front portion to the rear portion. By providing a first and a second channel which are crossing the longitudinal center line, upon wetting of the absorbent core 100, liquid is guided in the first and / or second elongate channel from left to right and / or from right to left, respectively, whilst flowing towards the crotch region or away from the crotch region, improving the liquid distribution, whereupon the liquid can be absorbed by the absorbent material. Further, by making the first and second channels cross the longitudinal center line, the channels may be longer compared to similar channels extending parallel to the longitudinal center line, resulting in a larger liquid distribution zone.

[0228] Preferably, the first and / or second crossing point are located at a distance of the transverse crotch line. For example, the first and / or second crossing point may be located in a front portion. In that way the position of the first and / or second can be optimized e.g. in function of whether the absorbent article is intended for a male or female person. However, in other embodiments, the first and / orsecond crossing point may be located on the transverse crotch line. When at a distance of the transverse crotch line, preferably, the distance between the first and / or second crossing point and the transverse crotch line is larger than 1% of the length of the absorbent core, preferably larger than 2%, even more preferably larger than 3%.

[0229] In certain embodiments with multiple first crossing points and / or multiple second crossing points, these multiple first and / or second crossing points may be located a different distances of the transverse crotch line, and may comprise e.g. two first crossing points, one in the front portion and one in the rear portion, and two second crossing points, one in the front portion (optionally corresponding with the first crossing point in the front portion), and one in the rear portion (optionally corresponding with the first crossing point in the rear portion).

[0230] Preferably, the first elongate channel 140, 170 extends both in the front portion and in the rear portion; and the second elongate channel 150, 160 extends both in the front portion and in the rear portion. In that manner a good liquid distribution from left to right and from front to rear can be obtained. Preferably, the first elongate and the second elongate channels are arranged symmetrically with respect to the longitudinal center line of the absorbent core. Preferably, a maximum distance between the first and the second elongate channel is between 15 and 70% of the width of the absorbent core, more preferably between 20 and 50%.

[0231] In an exemplary embodiment a maximum distance between the first and the second channel in the front portion is different from a maximum distance between the first and the second channel in the rear portion. In that manner the liquid distribution zone may be better adapted to the type of person wearing the absorbent article. For example, for a male person, a maximum distance between the distance between the first and the second channel near a front transverse edge may be larger than a maximum distance between the first and the second channel in a rear portion.

[0232] Preferably, the length of the first and second channel is larger than 10% of the length of the absorbent core, more preferably larger than 30%, even more preferably larger than 50%.

[0233] In an exemplary embodiment, the first and second channel together form a substantially X-shaped zone. Optionally the legs of the “X” may be interrupted to create one or more bridging zones.

[0234] FIG. 8H illustrates an embodiment of an absorbent article with an absorbent core 100 comprising three channels 140, 150, 180. In FIG. 8H, the CAS 400 is shown to extend over only a portion of thesurface area of the absorbent core 100, but it will be understood that it can also extend over the entire surface area of the absorbent core 100.

[0235] The channels comprise a first and second channel 140, 150 similar to the first and second channel of FIG. 8D, and a third channel 180 extending from the crotch region in the direction of the second transverse edge, wherein seen in a projection on a transverse direction the third channel 180 is located between the first and the second channel 140, 150. By having a first and a second channel in the front or rear portion and a third channel in the rear or front portion, respectively, it is possible to tailor the absorbent article to the wearer. For example, for a male person the first and second channel may be in the front portion and the third channel may be in the rear portion, whilst for a female person the first and second channel may be in the rear portion and the third channel in the front portion. Further it is possible to optimize the difference between the front and the rear portion for obtaining a unisex absorbent article.

[0236] Seen in a projection on the longitudinal direction of the absorbent core, the first and the second channel 140, 150 may extend over a length which is less than the length of the third channel 180. To fit better to the body the third channel 180 may be longer to extend over a longer part of the crotch region, for example the third channel may extend both in the front and the rear portion of the absorbent core. Preferably, the first and the second channel extend over a length which is at least 5% less, more preferably at least 10% less than the length of the third channel. Preferably the first and the second channel extend over a length which is at least 25%, more preferably at least 35%, even more preferably at least 45% of the length of the third channel.

[0237] In all embodiments described above, and in particular in the embodiments of FIG. 8A to 8H, preferably, each channel has a width wc measured in a transverse direction of the absorbent core, said width being at least 2% of the width of the absorbent core 100, preferably at least 3%, e.g. at least 5%.

[0238] The width wc of the channel may be constant through substantially the whole length of the channel (as shown in the figures) or may vary along its length. When the width varies along the length, then the above specified width percentages and values apply for the average width of the respective channel. Preferably, the one or more channels are formed by one or more absorbent material-free zones within the absorbent material deposition area of the absorbent core, and the width of a channel is considered to be the width of the material-free zone, disregarding the possible presence of core wrap within the channel.The absorbent core periphery may define any suitable shape, such as a “T,” “Y,” “hour-glass,” or “dog-bone” shape, for example. A “T shape may have a larger width in the front portion than in the rear portion of the absorbent core. An absorbent core periphery having a generally “dog bone” or “hour-glass” shape may taper along its width towards the middle or “crotch” region of the core. In this way, the absorbent core may have a relatively narrow width in an area of the absorbent core intended to be placed in the crotch region of an absorbent article.

[0239] For all embodiments described above, preferably, the one or more channels cover together at least 10%, preferably at least 20 %, more preferably at least 30% of a total length 1 of the absorbent core. The covered length may be realized with a single channel or with a combination of two or more channels. This will allow a good distribution over the entire absorbent core as well as a good formation of the channels / embankments and will give the absorbent article a tub-shape upon swelling of the absorbent core.

[0240] The absorbent article 100 may further comprise a wetness indicator preferably placed between two channels and / or in one or more channels and / or between a channel and an edge of the absorbent core. The wetness indicator may change appearance when contacted with liquid, e.g. the wetness indicator may be configured to generate a color change signal that changes appearance when contacted with liquid. The wetness indicator may comprise a composition that changes appearance when contacted with liquid, in particular a composition comprising a pH indicator and / or a water soluble dye. The composition may comprise a stabilizer, a colorant, and a matrix.

[0241] FIG. 9

[0242] FIG. 9 illustrates an embodiment of a disposable personal care article with front ears and back ears, such as a diaper or an adult incontinent garment. The absorbent article has two channels 1000, 2000. The capillary acceleration sheet 400 is shown to extend over only a portion of the surface area of the absorbent core 100, but it will be understood that it can also extend over the entire surface area of the absorbent core 100.

[0243] The channel portions 160, 170 are located at a distance of each other. As illustrated, the capillary acceleration sheet 400 may covers all four channel portions 140, 150, 160, 170. Preferably, the distance between the channel portion 140, 150 is different from the distance between the channel portions 160, 170. Preferably, the channel portions 140, 150 extend at least in the front portion 100a of the absorbent core 100, and the channel portions 160, 170 extend at least in the rear portion 100b of the absorbent core 100, wherein preferably the distance between the channel portions 140, 150 isbigger than the distance between the channel portions 160, 170. The channel portion 140 is connected to the channel portion 160 through a channel portion 180 and the channel portion 150 is connected to the channel portion 170 through a channel portion 190. Preferably, the channel portions 140, 150, 160, 170, 180, 190 comprise permanent attachment zones.

[0244] The absorbent core 100 has a front edge 133, a rear edge 134, and opposite longitudinal side edges 131, 132 which define an area Al. The absorbent material 130 is deposited in an area A2 within the area Al. The area A2 may be slightly smaller than the area Al.

[0245] A first distance dl2 between the front channel portions 140, 150 may be at least 5%, preferably at least 10% bigger, even more preferably at least 20% bigger than a second distance d34 between the rear channel portions 160, 170. This difference may be optimized in function of the desired used. For example, for male persons the difference may be bigger.

[0246] Seen in a projection on the longitudinal direction of the absorbent core 100, the channel portions 140, 150 may extend over a length 11 which is less than the length 13 of the channel portions 160, 170. To fit better to the body the channel portions 160, 170 which are closer to each other may be longer to extend over a longer part of the crotch region, for example the channel portions 160, 170 may extend both in the front and the rear portion 100a, 100b of the absorbent core 100. Preferably, the channel portions 140, 150 extend over a length 11 which is at least 5% less, more preferably at least 10% less than the length 13 of the channel portions 160, 170. Preferably the channel portions 140, 150 extend over a length 11 which is at least 25%, more preferably at least 35%, even more preferably at least 45% of the length 13 of the channel portions 160, 170.

[0247] FIGS. 10A to 10E

[0248] FIGS. 10A-E illustrate an example of a set of sealing bars 31, 31’ having a first sealing pattern. The sealing bars 31, 31’ may be intended to seal e.g. one or more channels 160. It will be understood that one or more sealing bars may be used in accordance with the one or more channels to be sealed. A detail of the sealing pattern is visible in the top view of FIG. 10B and in FIG. 10D which illustrates the areas where sealing will take place. Here the sealing pattern is a regular pattern of square shaped dots 1000. FIG. 10E shows a cross section and illustrates that the dots are achieved by protrusions 1010. Each protrusion 1010 preferably has a flat top surface forming a dot 1000 of the sealing pattern, and an inclined peripheral surface. If an absorbent particle were to be present near the flat top surface it can easily migrate in a recess delimited by the inclined peripheral wall.Preferably, the sealing pattern (i.e. the total surface area of the dots 1000) covers less than 80%, preferably less than 70%, more preferably less than 60%, even more preferably less than 50%, most preferably between 1 and 50% of the surface area of the one or more channels. For example, the sealing pattern covers between 1 and 50% of the total surface area of the one or more channels, or between 1 and 40%, or between 1 and 30%, or between 1 and 25%, or between 2 and 25%, or between 3 and 25%, or between 4 and 25%.

[0249] Such sealing pattern can provide a good resistance against the swell forces generated by liquid being captured in the superabsorbent particles by hydrogen bonds, but the sealing pattern equally can provide resistance against dry and wet superabsorbent particles frying to penetrate through the capillary acceleration sheet and through the sealing pattern after as well as during the sealing step of the manufacturing process. In that manner, any risk of dry or wet SAP particles coming into contact with sensitive skin upon wearing is avoided or reduced. Further, by having a reduced surface area that is being sealed in accordance with a pattern, any particles remaining in the one or more channel zones can easily migrate to a non-sealing area so that the risk of creating holes in the one or more channel zones is reduced or avoided.

[0250] Although a pattern of dots 100 is illustrated, the skilled person understands that other sealing patterns are possible, such as a line pattern e.g. a grid, etc. Also, the dots may have any shape, e.g. round, polygonal, etc. The line pattern may comprise one or more sets of parallel lines. When a first set of parallel lines and a second set of parallel lines are included, the lines of the first set may be oriented at a non-zero angle with respect to the lines of the second set.

[0251] Preferably, the sealing pattern comprises a large number of distinct sealing areas (here dots 1000) spread across the one or more channels. Preferably, the large number is larger than 10, more preferably larger than 20.

[0252] Preferably, the sealing pattern comprises a plurality of discrete elements (here dots 1000), and each discrete element has a first dimension dl in a first direction and a second dimension d2 in a direction perpendicular to the first direction. The first dimension dl is smaller than 2 mm, preferably smaller than 1.5 mm, more preferably smaller than 1 mm, e.g. between 0.1 and 0.7 mm or between 0.2 and 0.7 mm, or between 0.3 and 0.6 mm, e.g. 0.5 mm as illustrated. Preferably also the second dimension d2 is smaller than 2 mm, preferably smaller than 1.5 mm, more preferably smaller than 1 mm, e.g. between 0.1 and 0.7 mm or between 0.2 and 0.7 mm, or between 0.3 and 0.6 mm, e.g. 0.5 mm as illustrated. However, also line patterns are possible in which case the second distance d2 may be much longer than the first distance dl.Preferably, the distance between adjacent discrete elements (here dots 1000) is smaller than 10 mm, preferably smaller than 5 mm, more preferably smaller than 2 mm, e.g. between 0.1 and 2.0 mm or between 0.2 and 1.5 mm, or between 0.3 and 1.0 mm, e.g. 0.7 mm as illustrated. Preferably, the pitch distance d3 (=dl+d4) of the dot pattern is smaller than 10 mm, preferably smaller than 5 mm, more preferably smaller than 2 mm, e.g. 1.2 mm as illustrated.

[0253] Preferably, the angle a between adjacent inclined surfaces of the protrusions 1010 is between 60 and 120 degrees, more preferably between 70 and 110 degrees, even more preferably between 80 and 100 degrees.

[0254] Preferably, plurality of discrete elements (here dots 1000) is aligned along lines oriented at an angle |3 with respect to a longitudinal direction of the absorbent core. Preferably, the angle |3 is between 20 and 160 degrees, more preferably between 30 and 150 degrees.

[0255] Glossary

[0256] As used in the present application, the following terms have the following meanings:

[0257] "A", "an", and "the" as used herein refers to both singular and plural referents unless the context clearly dictates otherwise. By way of example, "an edge barrier" refers to one or more than one edge barrier.

[0258] "About" as used herein referring to a measurable value such as a parameter, an amount, a temporal duration, and the like, is meant to encompass variations of + / -20% or less, preferably + / -10% or less, more preferably + / -5% or less, even more preferably + / -1% or variations are appropriate to perform in the disclosed invention. However, it is to be understood that the value to which the modifier "about" refers is itself also specifically disclosed.

[0259] "Absorbent article", "absorbent garment", "absorbent product", "absorbing article", "absorbing garment", "absorbing product" and the like as used herein are used interchangeably and refer to devices that absorb and contain bodily exudates, and more specifically, refers to devices that are placed against or in proximity to the body of the wearer to absorb and contain the various liquids discharged from the body. Absorbent articles include but are not limited to feminine hygiene garments, baby diapers and pants, adult incontinence garments, various diaper and pants holders, liners, towels, absorbent inserts and the like."Absorbent core" as used herein refers to a three-dimensional part of the absorbent structure, comprising liquid-absorbing material, useful to permanently absorb and / or retain bodily exudates. "Absorbent component" as used herein refers to a structural constituent of an absorbent article, e.g., a piece of an absorbent core, such as one of multiple pieces in a multi-piece absorbent core.

[0260] "Absorbent element" as used herein refers to a part of a functional constituent of an absorbent structure, e.g., an acquisition layer, a dispersion layer, core layer or a release structure formed of a material or materials having particular liquid handling characteristics suitable for the specific function.

[0261] "Absorbent fibrous polymer material" as used herein refers to an absorbent polymer material which is in threadlike from such as fibers, filaments, and the like so as to be less flowable in the dry state than particulates.

[0262] "Absorbent insert" as used herein refers to a device adapted for insertion into an "Absorbent layer" as used herein refers to a term referring to a discrete, identifiable sheet-like or web-like element of an absorbent article which may remain detached and relatively movable with respect to another such element or may be attached or joined so as to remain permanently associated with another such element. Each absorbent layer may itself include a laminate or combination of several layers, sheets and / or webs of similar or diverse compositions.

[0263] "Absorbent polymer material", "absorbent gelling material", "AGM", "superabsorbent", "super absorbent material", "super absorbent polymer", "SAP" and the like as used herein are used interchangeably and refer to any suitable particulate (e.g., flaked, particulate, granular, or powdered) or fibrous cross linked polymeric materials that can absorb at least 5 times and preferably at least about 10 times or more its weight of an aqueous 0.9% saline solution as measured using the Centrifuge Retention Capacity test (EDANA 441.2-01).

[0264] "Absorbent polymer material area" as used herein refers to the area of the absorbent structure wherein adjacent layers are separated by a multiplicity of absorbent polymer material. Incidental contact areas between these adjacent layers within the absorbent particulate polymer material area may be intentional (e.g bond area's) or unintentional (e.g. manufacturing artifacts).

[0265] "Absorbent particulate polymer material" as used herein refers to an absorbent polymer material which is in particulate form such as powders, granules, flakes and the like so as to be flowable in the dry state.

[0266] Absorption" as used herein refers to the process by which a liquid is taken up within a material."Absorption rate" as used herein refers to the rate of absorption of liquid, i.e. the amount of liquid which is absorbed per unit of time, typically by an absorbent component, element and / or absorbent layer of the absorbent article, structure and / or core.

[0267] "Acquisition layer", "acquisition region", "acquisition surface" or "acquisition material" and the like as used herein refer to the layer overlying the absorbent core having a faster liquid uptake and / or distribution capability.

[0268] "Absorbency" is the ability of a material to take up fluids by various means including capillary, osmotic, solvent, chemical and / or other action.

[0269] "Adult incontinence garment" as used herein refers to absorbent articles intended to be worn by incontinent adults, for absorbing and containing bodily exudates.

[0270] "Adhesion" as used herein refers to the force that holds different materials together at their interface.

[0271] "Adhesive" as used herein refers to a material, which may or may not be flowable in solution or when heated, that is used to bond materials together.

[0272] "Adsorption" as used herein refers to the process by which a liquid is taken up by the surface of a material.

[0273] "Airlaying" as used herein refers to forming a web by dispersing fibers or particles in an air stream and condensing them from the air stream onto a moving screen by means of a pressure and / or vacuum; a web of fibers produced by airlaying is herein referred to an "airlaid"; an airlaid web bonded by one or more techniques to provide fabric integrity is herein referred to an "airlaid non wo ven".

[0274] "Apparent density", "density" as used herein refers to the basis weight of the sample divided by the caliper with appropriate unit conversions incorporated therein. Apparent density used herein has the unit g / cm3.

[0275] "Attach", "attached" and "attachment" as used herein are synonymous with their counterparts of the terms "fasten", "affix", "secure", "bind", "join" and "link"."Baby diaper" as used herein refers to absorbent articles intended to be worn by children, for absorbing and containing bodily exudates which the user draws up between the legs and fastens about the waist of the wearer.

[0276] "Baby pants" as used herein refers to absorbent articles marketed for use in transitioning children from diapers to underwear intended to cover the lower torso of children, so as to absorb and contain body exudates which article is generally configured like a panty garment and manufactured with a completed waist encircling portion, thereby eliminating the need for the user to fasten the article about the waist of the wearer.

[0277] "Back region" as used herein refers to the portion of an absorbent article or part thereof that is intended to be positioned proximate the back of a wearer.

[0278] "Backing" as used herein refers to a web or other material that supports and reinforces the back of a product.

[0279] "Basis weight" is the weight per unit area of a sample reported in grams per square meter, g / m2 or gsm.

[0280] "Bodily exudates", "body exudates", "bodily fluids", "body fluids", "bodily discharges", "body discharges", "fluid(s)", " liquid(s)", "fluid(s) and liquid(s) and the like as used herein are used interchangeably and refer to, but are not limited to urine, blood, vaginal discharges, breast milk, sweats and fecal matter.

[0281] "Binder", "adhesive", "glue", "resins", "plastics" and the like as used herein are used interchangeably and refer to substances, generally in a solid form (e.g. powder, film, fiber) or as a foam, or in a liquid form (e .g. emulsion, dispersion, solution) used for example by way of impregnation, spraying, printing, foam application and the like used for attaching or bonding functional and / or structural components, elements and materials, for example including heat and / or pressure sensitive adhesives, hot-melts, heat activated adhesives, thermoplastic materials, chemical activated adhesives / solvents, curable materials and the like.

[0282] "Bond strength" as used herein refers to the amount of adhesion between bonded surfaces. It is a measure of the stress required to separate a layer of material from the base to which it is bonded. "Capillary action", "capillarity", or "capillary motion" and the like as used herein are used to refer to the phenomena of the flow of liquid through porous media."Chassis" as used herein refers to a foundational constituent of an absorbent article upon which the remainder of the structure of the article is built up or overlaid, e.g., in a diaper, the structural elements that give the diaper the form of briefs or pants when configured for wearing, such as a backsheet, a topsheet, or a combination of a topsheet and a backsheet.

[0283] "Cellulose fibers" as used herein refers to naturally occurring fibers based on cellulose, such as, for example cotton, linen, etc; wood pulp fibers are one example of cellulose fibers; man-made fibers derived from cellulose, such as regenerated cellulose (rayon), or partially or fully acetylated cellulose derivatives (e.g. cellulose acetate or triacetate) are also considered as cellulose fibers.

[0284] "Cluster" or the like as used herein refers to an agglomeration of particles and / or fibers.

[0285] "Chemically stiffened fibers", chemically modified fibers", "chemically cross-linked fibers", "curly fibers" and the like as used herein are used interchangeably and refer to any fibers which have been stiffened by chemical means to increase stiffness of the fibers under both dry and aqueous conditions, for example by way of addition of chemical stiffening agents (e.g. by coating, impregnating, etc), altering the chemical structure of the fibers themselves (e.g. by cross-linking polymer chains, etc) and the like.

[0286] "Cohesion" as used herein refers to the resistance of similar materials to be separated from each other.

[0287] "Compartment" as used herein refers to chambers, cavities, pockets and the like.

[0288] "Comprise," "comprising," and "comprises" and "comprised of" as used herein are synonymous with "include", "including", "includes" or "contain", "containing", "contains" and are inclusive or open-ended terms that specify the presence of what follows e.g. a component and do not exclude or preclude the presence of additional, non-recited components, features, elements, members, steps, known in the art or disclosed therein.

[0289] "Coverstock" as used herein refers to a lightweight non-woven material used to contain and conceal an underlying absorbent core material; examples are the facing layer or materials that cover the absorbent cores of feminine hygiene garment s, baby diapers and pants and adult incontinence garments."Crotch region" of an absorbent article as used herein refers to about 50% of the absorbent article's total length (i.e., in the y-dimension), where the crotch point is located in the longitudinal center of the crotch region. That is, the crotch region is determined by first locating the crotch point of the absorbent article, and then measuring forward and backward a distance of 25% of the absorbent article's total length.

[0290] "Cross direction (CD)", "lateral" or "transverse" and the like as used herein are used interchangeably and refer to a direction which is orthogonal to the longitudinal direction and includes directions within ±45° of the transversal direction.

[0291] "Curing" as used herein refers to a process by which resins, binders or plastics are set into or onto fabrics, usually by heating, to cause them to stay in place; the setting may occur by removing solvent or by cross-linking so as to make them in soluble.

[0292] "Diaper", "conventional diaper", "diaper-like", "diaper-like garment" and the like as used herein are used interchangeably and refer to disposable absorbent articles, which typically include a front waist portion and a back waist portion which may be releasable connected about the hips of the wearer during use by conventional fasteners such as adhesive tape fasteners or hook and loop type fasteners. In use, the article is positioned between the legs of the wearer and the fasteners are releasable attached to secure the back waist portion to the front waist portion of the diaper, thereby securing the diaper about the waist of the wearer. The front waist portion and a back waist portion are connected by relatively non-stretchable or stretchable members (the term "stretchable" as used herein refers to materials that are extensible when forces are applied to the material, and offer some resistance to extension). Hence, such articles are generally not configured to be pulled up or down over the hips of the wearer when the fasteners are attached.

[0293] "Dispersion layer", "dispersion region", "dispersion surface" or "dispersion material" and the like as used herein refer to the layer overlying the absorbent core having a faster liquid uptake and dispersion capability.

[0294] "Disposable" is used herein to describe articles that are generally not intended to be laundered or otherwise restored or reused (i.e., they are intended to be discarded after a single use and, preferably, to be recycled, composted or otherwise disposed of in an environmentally compatible manner).

[0295] "Drylaying" as used herein refers to a process for making a nonwoven web from dry fiber; these terms apply to the formation of carded webs, as well as to the air laying formation of random webs;a web of fibers produced by drylaying is herein referred to as a "drylaid"; a drylaid web bonded by one or more techniques to provide fabric integrity is herein referred to a "drylaid nonwoven".

[0296] "Dry strength" as used herein refers to the strength of ajoint determined in dry state conditions, immediately after drying under specified conditions or after a period of conditioning in the standard laboratory atmosphere.

[0297] "Essentially cellulose free", “substantially fluffless” or "little to no cellulose fibers" as used herein refers to an absorbent article, structure, core component and / or element containing less than 20% by weight cellulosic fibers, less than 10% cellulosic fibers, less than 5% cellulosic fibers, no cellulosic fibers, or no more than an immaterial amount of cellulosic fibers which do not materially affect the thinness, flexibility or absorbency thereof.

[0298] "Essentially fluffless" or "little to no fluff pulp" as used herein refers to an absorbent article, structure, core, component and / or element containing less than 20% by weight fluff pulp, less than 10% fluff pulp, less than 5% fluff pulp, no fluff pulp, or no more than an immaterial amount of fluff pulp which do not materially affect the thinness, flexibility or absorbency thereof.

[0299] "Fabric" as used herein refers to a sheet structure made from fibers, filaments and / or yarns.

[0300] "Feminine hygiene garments" as used herein refer to absorbent hygiene articles intended to be worn by woman, for absorbing and containing body exudates.

[0301] "Fiber" as used herein refers to the basic threadlike structure from which nonwovens, yarns and textiles are made. It differs from a particle by having a length at least 4 times its width; "Natural fibers" are either of animal (wool, silk), vegetable (cotton, flax, jute) or mineral (asbestos) origin, while "Man-made fibers" may be either polymers synthesized from chemical compounds (polyester, polypropylene, nylon, acrylic etc.) or modified natural polymers (rayon, acetate) or mineral (glass). "Fiber" and "filament" are used interchangeably.

[0302] "Fluff pulp" or "Pulp fluff" as used herein refers to wood pulp specially prepared to be drylaid. The fibers can be either natural or synthetic or a combination thereof.

[0303] "Front region" as used herein refers to the portion of an absorbent article or part thereof that is intended to be positioned proximate the front of a wearer."Garment facing layer" as used herein refers to elements of the chassis that form the outer surface of the absorbent article, such as the backsheet, the side panels, the waist fasteners, and the like, when such elements are present.

[0304] "Heat activated adhesive" as used herein refers to a dry adhesive that is rendered tacky or fluid by application of heat or heat and pressure to the assembly.

[0305] "Heat sealing adhesive" as used herein refers to a thermoplastic adhesive which is melted between the adherent surfaces by heat application to one or both of the adjacent adherent surfaces.

[0306] "High loft" as used herein refers to general term of low density, thick or bulky fabrics.

[0307] "Hot-melt adhesive" as used herein refers to a solid material that melts quickly upon heating, then sets to a firm bond upon cooling; used for almost instantaneous bonding.

[0308] "Hydrophilic" as used herein refers to having an affinity for being wetted by water or for absorbing water.

[0309] "Hydrophobic" as used herein refers to lacking the affinity for being wetted by water or for absorbing water.

[0310] "Immobilization layer" as used herein refers to a layer able to be applied to the absorbent polymer material or absorbent polymer material area with the intent to gather, bond and / or immobilize absorbent material and / or absorbent layer.

[0311] "Join", "joined" and "joining" as used herein refers to encompassing configurations wherein an element is directly secured to another element by affixing the element directly to the other element, as well as configurations wherein the element is indirectly secured to the other element by affixing the element to an intermediate member or members which in turn is or are affixed to the other element.

[0312] "Knitting" as used herein refers to the technique for interlocking loops of fibers with needles or similar devices."Layer" refers to identifiable components of the absorbent article, and any part referred to as a "layer" may actually comprise a laminate or combination of several sheets or webs of the requisite type of materials. As used herein, the term "layer" includes the terms "layers" and "layered."

[0313] "Upper" refers to the layer of the absorbent article which is nearest to and / or faces the wearer facing layer; conversely, the term "lower" refers to the layer of the absorbent article which is nearest to and / or faces the garment facing layer. "Layer" is three dimensional structure with a x dimension width, y dimension length, and z-dimensions thickness or caliper, said x-y dimensions being substantially in the plane of the article, however it should be noted that the various members, layers, and structures of absorbent articles according to the present invention may or may not be generally planar in nature, and may be shaped or profiled in any desired configuration .

[0314] "Machine direction (MD)", "longitudinal" and the like as used herein are used interchangeably and refer to a direction running parallel to the maximum linear dimension of the structure and includes directions within ±45° of the longitudinal direction.

[0315] "Major surface" as used herein refers to a term used to describe the surfaces of greatest extent of a generally planar or sheet-like structural element and to distinguish these surfaces from the minor surfaces of the end edges and the side edges, i.e., in an element having a length, a width, and a thickness, the thickness being the smallest of the three dimensions, the major surfaces are those defined by the length and the width and thus having the greatest extent.

[0316] "Mass flow" as used herein refers to the flow of a liquid from one absorbent element or component to another absorbent element or component by channel flow action.

[0317] "Mechanical bonding" as used herein refers to a method of bonding fibers by entangling them. This can be achieved by needling, stitching with fibers or by the use of high-pressure air or water jets and the like.

[0318] "Nonwoven" as used herein refers to manufactured sheet, web or batt of directionally or randomly orientated fibers, bonded by friction, and / or cohesion and / or adhesion, excluding paper and products which are woven, knitted, tufted, stitch-bonded incorporating binding yarns or filaments, or felted by wet-milling, whether or not additionally needled. The fibers may be of natural or man-made origin and may be staple or continuous filaments or be formed in situ. Commercially available fibers have diameters ranging from less than about 0.001 mm to more than about 0.2 mm and they come in several different forms: short fibers (known as staple, or chopped), continuous single fibers(filaments or monofilaments), untwisted bundles of continuous filaments (tow), and twisted bundles of continuous filaments (yarn). Non wo ven fabrics can be formed by many processes such as melt blowing, spun bonding, solvent spinning, electrospinning, and carding. The basis weight of non wo ven fabrics is usually expressed in grams per square meter (gsm).

[0319] "Pant", "training pant", "closed diapers", "prefastened diapers", "pull-on diapers" and "diaper-pants" and the like as used herein are used interchangeably and refer to absorbent articles which are typically applied to the wearer by first leading the feet into the respective leg openings and subsequently pulling the pants from the feet to waist area over the hips and buttocks of the wearer and which are capable of being pulled up or down over the hips of the wearer. Typically, such articles may include a front waist portion and a back waist portion which may be connected about the hips of the wearer by integral or releasable members. A pant may be preformed by any suitable technique including, but not limited to, joining together portions of the article using refastenable and / or nonrefastenable bonds (e.g., seam, weld, adhesive, cohesive bond, fastener, etc.). A pant may be preformed anywhere along the circumference of the article (e.g., side fastened, front waist fastened).

[0320] "Polymer" as used herein refers to but is not limited to, homopolymers, copolymers, such as for example, block, graft, random and alternating copolymers, terpolymers, etc. and blends and modifications thereof. Unless otherwise specifically limited, the term "polymer" includes all possible spatial configurations of the molecule and include, but are not limited to isotactic, syndiotactic and random symmetries.

[0321] "Rear" as used herein refers to the portion of an absorbent article or part thereof that is intended to be positioned proximate the back of the wearer.

[0322] "Release structure", "release region", "release surface" or "release material" and the like as used herein are used interchangeably and refer to a structure in fluid communication with the absorbent core having a larger relative liquid absorption capacity and / or rate allowing it to quickly take up, temporarily hold and releasing liquids.

[0323] "Resin" as used herein refers to a solid or semisolid polymeric material.

[0324] "Thermobonding" as used herein refers to a method of bonding fibers by the use of heat and / or high-pressure.

[0325] "Thermoplastic" as used herein refers to polymeric materials that have a melting temperature and can flow or be formed into desired shapes on the application of heat at or below the melting point."Ultrasonic" as used herein refers to the use of high frequency sound to generate localized heat through vibration thereby causing thermoplastic fibers to bond to one another.

[0326] "Water-absorbing", "liquid-absorbing", "absorbent", "absorbing" and the like as used herein are used interchangeably and refer to compounds, materials, products that absorb at least water, but typically also other aqueous fluids and typically other parts of bodily exudates such as at least urine or blood.

[0327] "Wearer facing layer" as used herein refers to elements of the chassis that form the inner surface of the absorbent article, such as the topsheet, the leg cuffs, and the side panels, etc., when such elements are present.

[0328] "Weaving" as used herein refers to the process of interlacing two or more sets of yarns at right angles to form a fabric; a web of fibers produced by weaving is herein referred to as a "woven".

[0329] "Web material" as used herein refers to an essentially endless material in one direction, i.e. the longitudinal extension or the length, or the x- direction in Cartesian coordinates relative to the web material. Included in this term is an essentially unlimited sequence of pieces cut or otherwise separated from an essentially endless material. Often, though not necessarily, the web materials will have a thickness dimension (i.e. the z-direction) which is significantly smaller than the longitudinal extension (i.e. in x-direction). Typically, the width of web materials (they-direction) will be significantly larger than the thickness, but less than the length. Often, though not necessarily, the thickness and the width of such materials is essentially constant along the length of the web. Without intending any limitation, such web materials may be cellulosic fiber materials, tissues, woven or nonwoven materials and the like. Typically, though not necessarily, web materials are supplied in roll form, or on spools, or in a folded state in boxes. The individual deliveries may then be spliced together to form the essentially endless structure. A web material may be composed of several web materials, such as multilayer non-woven, coated tissues, nonwoven / film laminates. Web materials may comprise other materials, such as added binding material, particles, hydrophilizing agents and the like.

[0330] "Wet burst strength" is a measure of a layer's ability to absorb energy, when wet and subjected to deformation normal to the plane of the web."Wet strength" as used herein refers to the strength of a joint determined immediately after removal from a liquid in which it has been immersed under specified conditions of time, temperature and pressure. The term is commonly used in the art to designate strength after immersion in water.

[0331] "Wetlaying" as used herein refers to the forming a web from an aqueous dispersion of fibers by applying modified paper making techniques; a web of fibers produced by wetlaying is herein referred to as a "wetlaid".

[0332] "Wood pulp" as used herein refers to cellulosic fibers used to make viscose rayon, paper and the absorbent cores of products such as feminine hygiene garments, baby diapers and pants and adult incontinence garments.

[0333] "X-y dimension" as used herein refers to the plane orthogonal to the thickness of the article, structure or element. The x- and y-dimensions correspond generally to the width and length, respectively, of the article, structure or element.

[0334] "Z-dimension" as used herein refers to the dimension orthogonal to the length and width of the article, structure or element. The z-dimension corresponds generally to the thickness of the article, structure or element.

Claims

57CLAIMS1. An absorbent article comprising a liquid pervious topsheet (300), a liquid impervious backsheet (200), absorbent material (130) positioned between the liquid pervious topsheet and the liquid impervious backsheet, and a bottom distribution assembly (120) between the absorbent material and the liquid impervious backsheet, wherein the absorbent material (130) comprises cellulosic fluff pulp (131) and first superabsorbent particles (132) and is arranged such that one or more channels (160, 170) are formed, wherein less absorbent material per surface area is present in the one or more channels compared to an area around the one or more channels, wherein preferably substantially no absorbent material is present in the one or more channels, wherein the bottom distribution assembly comprises a first non wo ven (121), wherein the first non wo ven (121) comprises second superabsorbent particles (142).

2. The absorbent article of claim 1, wherein the first non wo ven is in direct contact with the absorbent material.

3. The absorbent article of claim 1 or 2, wherein one or more physical and / or chemical properties of the first superabsorbent particles (132) and second superabsorbent particles (142) are different, wherein preferably the chemical properties are different.

4. The absorbent article of any one of the previous claims, wherein the centrifuge retention capacity, CRC, of the first superabsorbent particles (132) and the CRC of the second superabsorbent particles (142) are different, wherein preferably the difference is at least 2g / g, more preferably at least 3g / g even more preferably at least 4g / g.

5. The absorbent article of claim 4, wherein the CRC of the first superabsorbent particles is lower than the CRC of the second superabsorbent particles.

6. The absorbent article of any one of the previous claims, wherein the vortex of the first superabsorbent particles and the vortex of the second superabsorbent particles are different, wherein preferably the difference is at least 10s, more preferably at least 15s even more preferably at least 20s.

7. The absorbent article of claim 6, wherein the vortex of the first superabsorbent particles (132) is lower than the vortex of the second superabsorbent particles (142).

588. The absorbent article of any one of the previous claims, wherein the absorption against pressure, AAP of the first superabsorbent particles and the AAP of the second superabsorbent particles are different, wherein preferably the difference is at least 2g / g, more preferably at least 3 g / g, measured at 4.8 kPa.

9. The absorbent article of claim 8, wherein the AAP of the first superabsorbent particles (132) is higher than the AAP of the second superabsorbent particles (142).

10. The absorbent article of any one of the previous claims, wherein an amount of the first superabsorbent particles in the absorbent material is higher than an amount of the second superabsorbent particles in the first nonwoven.

11. The absorbent article of any one of the previous claims, wherein the bottom distribution assembly comprises a second non wo ven (122) arranged between the backsheet and the first non wo ven (121) and configured to form a barrier for the second superabsorbent particles, wherein preferably the second nonwoven comprises a spunbond layer and / or a meltblown layer and / or wherein the second nonwoven is a carded thermobonded nonwoven.

12. The absorbent article of claim 11, wherein the second non wo ven has a second average density which is higher than a first average density of the first nonwoven, wherein a difference between the first average density and the second average density is higher than 20 kg / m3, preferably higher than 30 kg / m3 more preferably higher than 40 kg / m3, even more preferably between 50 and 150 kg / m3, most preferably between 60 and 140 kg / m3.

13. The absorbent article of claim 11 or 12, wherein the first nonwoven has an average density between 20 and 400 kg / m3, preferably between 20 and 300 kg / m3, more preferably between 20 and 250 kg / m3; and / or wherein the second non wo ven has an average density between 50 and 400 kg / m3.

14. The absorbent article of any one of the claims 11 to 13, wherein the second non wo ven has a basis weight between 8 and 60 g / m2, preferably between 10 and 50 g / m2.

15. The absorbent article of any one of the claims 1 to 10, wherein the bottom distribution assembly comprises a second nonwoven (122’) arranged between the backsheet and the first nonwoven and wherein the second nonwoven comprises third superabsorbent particles (152).5916. The absorbent article of claim 15, wherein one or more physical and / or chemical properties of the second superabsorbent particles (142) and third superabsorbent particles (152) are different, wherein preferably the chemical properties are different.

17. The absorbent article of claim 15 or 16, wherein the centrifuge retention capacity, CRC, and / or the vortex and / or the AAP of the second superabsorbent particles (142) and the centrifuge retention capacity, CRC, and / or the vortex and / or the AAP of the third superabsorbent particles (152) are different.

18. The absorbent article of any one of the claims 15 to 17, wherein an amount of the second superabsorbent particles in the first nonwoven is different from an amount of the third superabsorbent particles in the second nonwoven.

19. The absorbent article of any one of the claims 15 to 18, further comprising a third non wo ven (123) between the second non wo ven and the backsheet, said third non wo ven being preferably configured to form a barrier for the third superabsorbent particles.

20. The absorbent article of any one of the claims 15 to 19, wherein the second nonwoven has a basis weight between 15 and 150 g / m2, preferably between 20 and 130 g / m2.

21. The absorbent article of any one of the previous claims, wherein the first non wo ven is any one of the following: a carded through-air-bonded nonwoven, a spunlace nonwoven.

22. The absorbent article of any one of the previous claims, wherein an amount of the cellulosic fluff pulp in the absorbent material is below 350 g / m2, preferably below 300 g / m2, more preferably below 250 g / m2, even more preferably below 200 g / m2, e.g. between 50 g / m2 and 180 g / m2.

23. The absorbent article of any one of the previous claims, wherein an amount of the first superabsorbent particles in the absorbent material is between 100 g / m2 and 350 g / m2.

24. The absorbent article of any one of the previous claims, wherein an amount of the second superabsorbent particles in the absorbent material is above 15 g / m2, preferably between 20 g / m2 and 200 g / m2.

25. The absorbent article of any one of the previous claims, wherein the first non wo ven has a basis weight between 15 and 150 g / m2, preferably between 30 and 85 g / m2, more preferably between 35 and 80 g / m2.6026. The absorbent article of any one of the previous claims, further comprising a top core wrap sheet and / or a capillary acceleration sheet between the absorbent material and the topsheet, wherein the first nonwoven, and optionally also the optional second nonwoven, is attached to the top core wrap sheet and / or the capillary acceleration sheet at least in a portion of the one or more channels.

27. The absorbent article of the previous claim, wherein the first nonwoven, and optionally also the optional second nonwoven if present, is attached along a periphery to the top core wrap sheet and / or the capillary acceleration sheet.

28. The absorbent article of claim 26 or 27, wherein the first nonwoven, and optionally also the optional second nonwoven is glued to the top core wrap sheet and / or the capillary acceleration sheet at least in a portion of the one or more channels.

29. The absorbent article of any one of the claims 26 to 28, wherein the first nonwoven, and optionally also the optional second nonwoven is sealed in accordance with a sealing pattern to the top core wrap sheet and / or to the capillary acceleration sheet at least in a portion of the one or more channels, wherein preferably the sealing is realized by heat and / or pressure and / or ultrasonic energy.

30. The absorbent article of claim 29, wherein the sealing pattern covers less than 70%, preferably less than 60%, more preferably less than 50%, even more preferably between 1 and 40% of the surface area of the one or more channels.

31. The absorbent article of any one of the previous claims, wherein substantially no second superabsorbent particles (142) are present in the one or more channels (160).

32. A method for manufacturing an absorbent article, preferably an absorbent article according to any one of the previous claims, comprising the steps of providing a liquid pervious topsheet and a liquid impervious backsheet; arranging an absorbent material (130) comprising first superabsorbent particles (132), between a bottom distribution assembly (120), on one side, and a top core wrap sheet (110) and / or a capillary acceleration sheet, on the other side, such that one or more channels are formed, wherein less absorbent material per surface area is present in the one or more channels compared to areas around the one or more channels, wherein preferably substantially no absorbent material is present in the one or more channels; and arranging the liquid pervious topsheet at the side of top core wrap sheet and / or the capillary acceleration sheet and the liquid impervious backsheet at the sideof the bottom distribution assembly, wherein the bottom distribution assembly (120) comprises a first nonwoven (121), wherein the method further comprises arranging second superabsorbent particles (142) in said first nonwoven.

33. The method of claim 32, wherein the first non woven is arranged in contact with the absorbent material.

34. The method of claim 32 or 33, wherein the first nonwoven is attached to the top core wrap sheet and / or the capillary acceleration sheet at least in a portion of the one or more channels, e.g. by gluing and / or sealing.

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