Absorbent composite from melt-blown fibers and superabsorbents

Abstract

Nonwoven composite structures include an open network of melt-blown polymer filaments that are co-deposited with SAP particles. The nonwoven composites can retain the SAP without requiring the use of adhesives, and the filaments exhibit sufficient elasticity to allow for SAP swelling. The nonwoven composites can be incorporated into absorbent articles, such as diapers.

Description

ATTY DOCKET: DSGI-1015WOABSORBENT COMPOSITE FROM MELT-BLOWN FIBERS AND SUPERABSORBENTSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of United States Provisional Patent Application No. 63 / 750,094 (pending), filed on January 27, 2025, and entitled “Absorbent Composites from Thermoplastic Melt-Blown Fibers and Superabsorbents”, the entirety of which is incorporated herein by reference.FIELD

[0002] The present disclosure relates to composite materials, including absorbent composites, to articles including the same, and to methods and systems for making the same. The composite materials can be incorporated into absorbent articles, such as diapers, sanitary napkins, absorbent pads, or the like. The composite materials include a combination of thermoplastic melt-blown fibers or filaments and superabsorbent particles.BACKGROUND

[0003] Absorbent composites typically include particles of superabsorbent polymer and nonwoven materials. Fluff or pulp is sometimes used to, in part, form a matrix of material that retains the particles of superabsorbent polymer. Some technologies have been developed that are “fluffless” or “pulpless”. These fluffless / pulpless technologies often rely on the use of premade bulky nonwovens that the superabsorbent polymer is placed into, sometimes with adhesive to retain the particles of superabsorbent polymer in the bulky nonwoven. Such technologies can be costly, require additional steps and / or materials, and the adhesive can impair the performance of the superabsorbent polymer by blocking the absorption of water and resisting the expansion forces within the particles as the particles expand and swell.

[0004] It would be desirable to produce consistent absorbent composites in a process that minimizes waste, cost, the number raw materials, and / or the amount of raw materials.BRIEF SUMMARY

[0005] The present disclosure includes nonwoven composites. Preferably, the nonwoven composites include a nonwoven web of filaments of a melt-blown polymer and particles of superabsorbent polymer within the nonwoven web. The nonwoven composites can be formed by melt-blowing a polymer to form a plurality of melt-blown polymer filaments andATTY DOCKET: DSGI-1015WOintroducing and / or depositing a plurality of particles of superabsorbent polymer onto and within the web of melt-blown polymer filaments. The melt-blown polymer filaments are at least partially molten and tacky during the depositing such that the SAP particles are ensnared within the web or adhere to the filaments. Further, the web is sufficiently dense but open to facilitate impregnation and integration of absorbent particles of advantageous shapes, sizes, and properties on and within the web. The method includes cooling and solidifying the melt-blown polymer filaments to form the resulting absorbent nonwoven composite. The nonwoven composite includes the particles of superabsorbent polymer dispersed within a network of the melt-blown polymer filaments. The nonwoven composites can be made using a system that includes a melt-blown extruder, a SAP applicator, and a conveyer.

[0006] More preferably, an extruded filament array of (mostly) space-apart and interconnected or interlaced filaments form a three-dimensional network. The network is an open web with interstitial volumes albeit with open spaces at the micro level such that the suspended web may appear more like a solid curtain output of an extruder. Twhus, in the preferred process, a three-dimensional curtain of tacky, thermoplastic filaments is directed downwardly and is intersected by continuous stream of SAP particles that is advantageously directed at angle to the curtain. More preferably, the SAP stream is directed at selected velocities (e.g., relative to the curtain) and constituencies, and an angle less than 90 degrees (and greater than 30 degrees from the direction of curtain travel (i.e., the horizontal plane) to achieve a desired integrated, SAP-filament structure. In practice, the SAP stream causes SAP particles to impregnate the filament curtain or array - penetrating the curtain to a desired degree. Downstream, the resulting absorbent composite includes the filament web penetrated (superficially and / or beyond) by an assortment of spaced-apart SAP particles (which may be of varying or different sizes or shapes), whereby, the web provides a scaffolding structure about the SAP particles. The scaffolding structure supports and / or contains the SAP while also providing interconnected, interstitial spaces therebetween that contain and help channel fluid flow.

[0007] Thus, as one aspect of the disclosure, the absorbent composite includes a dispersion or suspension of SAP particles disposed in a web of filaments. The web provides a scaffolding construct about the SAP particles. The particles and the filaments are interlaced or interconnected and interstitial voids or spaces are provided throughout the web and in between the particles and the filaments. The network of voids or spaces provide a resilient network of fluid channels or reservoirs and together with interconnected filaments and SAP particle provide a fluidly communicative absorbent body. In some preferred embodiments, the filaments are elastomers and more preferably, thermoplastic polyurethane, Further, the SAPATTY DOCKET: DSGI-1015WOdispersed in the scaffold construct are of different sizes and, by way of a preferred impregnating process, are dispersed in the thickness direction of the filament web and composite in accordance with a gradient. That is larger SAP particles are predominantly at or near the surface, while smaller particulate penetrates and predominate deeper into the web.

[0008] In preferred embodiments, the resulting SAP-fibers composite are further disposed on nonwoven substrate and further yet, a second nonwoven substrate is disposed on the other or opposite side of the composite. The resulting multi-layer sandwich structure can then readily serve as an absorbent composite core for integration in to a disposable absorbent article such as a diaper, training pants, feminine napkin and hygiene products, and the like. The absorbent composite may also serve as an absorbent core or primary absorbent substrate of other disposable absorbent articles or products such as tissues, wipes, cleaning products and the like with further modifications to the process and articles generally known and associated with traditional personal disposable absorbent articles.

[0009] In further embodiments, the process and composite described above employ elastomers such as thermoplastic polypropylene as filaments of the web and scaffold. In this construction, the elastomer filaments impart stretch and additional resiliency to the web and allows for movement of the filaments about and around the SAP especially during SAP swell. The elastomer also provides improved tackiness relative to the SAP, thereby helping secure or scaffold the SAP dispersion.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] So that the manner in which the features and advantages of the compositions, articles, systems and methods of the present disclosure may be understood in more detail, a more particular description briefly summarized above may be had by reference to the embodiments thereof which are illustrated in the appended drawings that form a part of this specification.

[0011] FIG. 1A depicts a system for forming melt-blown (MB) fibers or filaments in accordance with embodiments of the present disclosure.

[0012] FIG. IB is a detail, cross-sectional view of a portion of FIG. 1A.

[0013] FIG. 2 depicts an extruder for extrusion of plastics and elastomers in accordance with embodiments of the present disclosure.

[0014] FIG. 3 depicts a venturi device used to collect and convey superabsorbent polymer (SAP) in accordance with embodiments of the present disclosure.ATTY DOCKET: DSGI-1015WO

[0015] FIG. 4 depicts a system including a single melt-blown applicator and single SAP applicator configured for forming a SAP-MB nonwoven composite in accordance with embodiments of the present disclosure.

[0016] FIG. 5 depicts a portion of a system including a dual melt-blown applicator and single SAP applicator configured for forming a SAP-double MB nonwoven composite in accordance with embodiments of the present disclosure.

[0017] FIG. 6 depicts a portion of a system including a triple melt-blown applicator and double SAP applicator configured for forming a double SAP-triple MB nonwoven composite in accordance with embodiments of the present disclosure.

[0018] FIG. 7 depicts a portion of a system including a triple melt-blown applicator, additive applicator, and double SAP applicator configured for forming a double SAP-triple MB nonwoven composite with an additive in accordance with embodiments of the present disclosure.

[0019] FIG. 8A depicts a SAP-MB nonwoven composite in accordance with embodiments of the present disclosure.

[0020] FIG. 8B is a detail view of a portion of FIG. 8A.

[0021] FIG. 8C depicts a SAP -double MB nonwoven composite in accordance with embodiments of the present disclosure.

[0022] FIG. 8D is a detail view of a portion of FIG. 8C.

[0023] FIG. 8E depicts a double SAP -triple MB nonwoven composite in accordance with embodiments of the present disclosure.

[0024] FIG. 8F is a detail view of a portion of FIG. 8E.

[0025] FIG. 8G is a top view of the SAP-MB nonwoven composite of FIG. 8A.

[0026] FIG. 9A depicts a system for forming a nonwoven composite in accordance with the present disclosure including a melt-blown extruder and a SAP applicator.

[0027] FIG. 9B is a detail view of a portion of FIG. 9A showing the impact of the SAP with the melt-blown filaments.

[0028] FIG. 9C illustrates the angle of impact between the streams of SAP and fibers or filaments.

[0029] FIGS. 10A is a photograph of exemplary melt-blown sachets containing SAP before exposure to water in accordance with embodiments of the present disclosure.

[0030] FIGS. 10B-10G are photographs of exemplary melt-blown sachets, with varying amount of elastomer and containing SAP, after exposure to water, showing the effect of elastomer in accordance with embodiments of the present disclosure.ATTY DOCKET: DSGI-1015WO

[0031] FIGS. 11A-11F are images of filaments of the sachets of FIGS. 10B-10G, respectively, produced with elastomers in accordance with embodiments of the present disclosure.

[0032] FIG. 12 is a graph of average SAP loss by elastomer content for different polymers.

[0033] FIG. 13 depicts a nonwoven composite specimen in both the wet and dry states.

[0034] FIG. 14 depicts a nonwoven composite after absorption showing the three-dimensional response of the composite.

[0035] FIG. 15 depicts a nonwoven composite after absorption showing the three-dimensional response of the composite.

[0036] FIG. 16 is an image of nonwoven composites of various polymer compositions, prior to absorption of liquid.

[0037] FIG. 17A depicts a nonwoven composites both before and after absorption of liquid.

[0038] FIG. 17B is a detail view of a portion of FIG. 17A.

[0039] FIG. 18 depicts the nonwoven composites of FIG. 16 after absorption of liquid.

[0040] FIG. 19 depicts two nonwoven composites after absorption of liquid.

[0041] FIGS. 20-23 are graphs of free swell rate over time for nonwoven composites of various polymer compositions.

[0042] Compositions, articles, systems and methods according to present disclosure will now be described more fully with reference to the accompanying drawings, which illustrate various exemplary embodiments. Concepts according to the present disclosure may, however, be embodied in many different forms and should not be construed as being limited by the illustrated embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough as well as complete and will fully convey the scope of the various concepts to those skilled in the art and the best and preferred modes of practice.DETAILED DESCRIPTION

[0043] The present disclosure includes composites of thermoplastic melt-blown fibers or filaments and superabsorbent particles. In some embodiments, the composites are absorbent composites, such as for use in diapers, sanitary napkins, or the like. The present disclosure also includes methods of making the composites and systems for making the composites. The composites can be made using a melt-blowing process to produce a web of preferred fibers or filaments and integrating SAP (and optionally other fibers and / or particles) into or with theATTY DOCKET: DSGI-1015WOweb of the melt-blown fibers or filaments. In some embodiments the MB fibers or filaments include polypropylene (PP) fibers or filaments. In other embodiments the MB fibers or filaments include thermoplastic polyurethane (TPU) fibers or filaments. As used herein, the terms “fibers” and “filaments” are not limited by length and are used interchangeably herein to refer to the interlaced or interconnected elements that make up the preferred web construct Process to Integrate SAP and MB Fibers or Filaments

[0044] The present absorbent composite forming process includes generating a web of melt-blown filaments or fibers and integrating SAP therein or therewith, and optionally other fibers and / or particles, with MB fibers or filaments. In one aspect of the disclosure, both of these subprocesses are dynamic processes and the system of making the composite is configured such that two streams are generated and the two subprocesses or streams intersect. Advantageously, both the elements or constituency of each stream as well as energy (e.g., momentum / kinetic and heat) carried by the streams (imparted by each subprocess) intersect. The melt-blown fibers or filaments can be formed via a hot air extrusion process. Notably, heat carried by the filament stream (and by the SAP stream in further embodiments) are utilized in the forming process and / or transferred to the resulting process. Among other things, the heat facilitates adherence between Sap and suspended filaments, and further, with little use of, or avoidance entirely of adhesive in the composite. Before describing the formation of the composites herein, a brief description of the extrusion process is described with reference to FIGS. 1A-2.

[0045] With reference to FIGS. 1A and IB, an exemplary melt-blown system 100, and associated process, for making the composites is shown and described. The system 100 shown in FIGS. 1A and IB does not depict the integration of SAP into the MB fibers or filaments, which is shown in other Figures herein. System 100 includes extruder 102, which is driven by drive motor 104. A hopper 106 containing pellets 108 of polymer is coupled with the extruder 102. The hopper 106 is positioned and configured to provide the pellets 108 into the extruder 102. A die head 112 is coupled with the extruder 102. The die head 112 is also coupled with hot air sources 114. Valves 116 are positioned to regulate the flow of hot air 118 through conduits 120 from the hot air sources 114 to the die head 112. Within the extruder 102, the pellets 108 are mixed and melted to form a polymer melt 110. The polymer melt 110 is forced through the die head 112 and out of die holes 122 in the die head 112, along with the hot air 118, as melt-blown fibers or filaments 124. The melt-blown fibers or filaments 124 are carried out of the extruder 102 by hot air streams 118. After exiting the extruder 112, the melt-blown fibers or filaments 124 are deposited onto a collection surface, such as the drum collector 126,ATTY DOCKET: DSGI-1015WOto form a mat or web of melt-blown polymer fibers or filaments 128. The process can utilize a single melt-blown head or multiple melt-blown heads to form the nonwoven filaments of polymer (i.e., melt-blown fibers or filaments 124). The mat of fibers or filaments 128 formed by the melt-blown fibers or filaments 124 functions, at least partially, as a scaffold structure onto which the SAP is distributed and entrapped within.

[0046] FIG. 2 depicts details of an extruder 202 showing internal components thereof. Similar to extruder 102, extruder 202 is driven by motor 204, and includes hopper 206 of polymer pellets 208 and die head 212. The extruder 202 includes three primary sections, including a feed section 201, a compression section 203, and a metering section 205. Within the feed section 201, the feedstock of pellets 208 is moved from the hopper 206 into the barrel 207 of the extruder 202 for heating. Heaters 209 coupled with the barrel 207 melt the pellets 208 to form the polymer melt 210. Within the compression section 203, the polymer melt 210 is fluidized, air mixed in the polymer melt 210 is extracted, and the polymer melt 210 is compressed. The fluidization, air extraction, and compression are at least partially achieved via pressurization and heating including the turning of a screw 211, positioned within the barrel 207, by the motor 204 and the heating via heaters 209. Within the metering section 205, the polymer melt 210 is homogenized and pressure is increased sufficiently to force the polymer melt 210 through the breaker plate 213 and die hole 222 of the die head 212 as a melt-blown fiber or filaments 224 extrudate. The melt-blowing system disclosed herein is not limited to the particular embodiments shown in FIGS. 1A-2 and may include other system components capable of forming molten polymer fibers or filaments. Similarly, the process disclosed herein is not limited to the particular steps described in reference to FIGS. 1A-2 and may exclude certain steps described and / or include additional steps for forming molten polymer fibers or filaments.Venturi Device

[0047] With reference to FIG. 3, the particles of superabsorbent polymer can be delivered to a hot airstream, for subsequent combination with the MB fibers or filaments, via use of a venturi device. Venturi device 330 includes a suction chamber 332 having an input 334 and an output 336. Venturi device 330 includes a container 338 containing SAP 340 (preferably of varying sizes (diameter)). The container 338 is in fluid communication with the suction chamber 332 via SAP inlet 342. In operation, pressurized air 333 is forced through the input 334 and then through the suction chamber 332. As the air 333 is constricted into the channel of the output 336 the venturi effect provides suction to draw SAP 340 from the SAP container 338, through the SAP inlet 342, and into the suction chamber 332. The SAP 340 isATTY DOCKET: DSGI-1015WOmixed with the air stream 333 as it is forced through the output 336, forming a SAP-air stream 344. As described in more detail elsewhere, the SAP-air stream 344 is then directed or conveyed towards hot melt-blown filaments (e.g., as the filaments exit the extruder) for combination of the SAP with the MB fibers or filaments. In further embodiments, air inlet velocity, venturi sizes or constrictions, SAP sizes an dother vriable may be manipulated to achieve desired composite properties. The venturi process or effect may be ceased, slowed or accelerated as well.System and Method for Making Composites

[0048] Embodiments of the process for forming the composites and absorbent cores disclosed herein include use of one or more melt-blown applicators (e.g., melt-blown extruder), one or more conveyors, one or more SAP applicators (e.g., venturi device and / or nozzle) and, optionally, one or more additives applicators. The process disclosed herein are used to form SAP -based composites by melt-blowing a polymer fiber or filament to from a filament network of the melt-blown polymer fibers or filaments and then dynamically integrating SAP into the filament network. The SAP is impacted with the filament network of the melt-blown polymer fibers or filaments such that at least a portion of the SAP embeds into the melt-blown polymer fibers or filaments.

[0049] FIG. 4 depicts a system for forming an absorbent composite in accordance with embodiments of the present disclosure. System 400 includes a melt-blown fiber applicator 402, such as a melt-blowing extruder with an outlet or nozzle. The melt-blown fiber applicator 402 forms and dispenses (e.g., extrudes) melt-blown fibers or filaments 424.

[0050] The melt-blown fiber applicator 402 can be or include an extruder, such as those shown and described in reference to FIGS. 1A-2. However, the melt-blown fiber applicator 402 is not limited to being an extruder in accordance with FIGS. 1A-2. The melt-blown fiber applicator 402 is an apparatus that is configured to provide the melt-blown fibers or filaments 424. In some embodiments, the melt-blown fiber applicator 402 provides the melt-blown fibers or filaments 424 as hot melt-blown fibers or filaments via a hot air stream. As previously described, the melt-blown fiber applicator 402 can include a pellet hopper (not shown) that contains pellets of the raw material from which the melt-blown fibers or filaments 424 are formed. The pellets can include pellets of polypropylene, TPU, or other polymer; an elastomer; a wetting agent or other additives; or combinations thereof. While polypropylene and TPU are used in some embodiments of the melt-blown fibers or filaments 424, the present disclosure is not limited to polypropylene or TPU and may include other polymers, such as other polyolefins. As described in more detail in reference to FIGS. 1A-2, in operation the raw materials (e.g.,ATTY DOCKET: DSGI-1015WOpellets) are drawn into the extruder from the hopper and fed through the extruder via a screw, under increasing temperature and pressure, at least partially melting the raw materials. The die head of the extruder is positioned as an output such that the melted raw material is forced through the die head as melt-blown fibers or filaments 424. In operation, hot air is pumped through the die head to pick-up the melted raw material and propel the melted raw material out of small nozzles (spinnerets) built into the die head. The dimensions of the nozzles of the die head affect the dimensions of the resultant melt-blown fibers or filaments 424. In some embodiments it is desirable that the pellets of raw material are well mixed. Superior mixing of the pellets can be achieved by compounding the pellets of raw material prior to introduction into the extruder. Compounding of the pellets of raw material involves providing the pellets of raw material in the appropriate relative concentrations, and melting and / or mixing the pellets of raw material thoroughly to ensure an even distribution of the components in the mixture. The mixture, also referred to as a pre-melt mixture, can then be either fed directly into the extruder or cooled, re -pelletized, and then stored or transported to the extruder.

[0051] System 400 includes a SAP applicator 438 (e.g. , a nozzle, hopper and / or venturi device). The SAP applicator 438 is positioned and arranged to dispense SAP 440 onto the melt-blown fibers or filaments 424. For example, a pressurized air stream can be provided from air source to a portion of the SAP applicator 438 to force the SAP 440 out of the SAP applicator 438 (e.g., see FIG. 3 and the description thereof).

[0052] The melt-blown fiber applicator 402 and the SAP applicator 438 are arranged such that the stream of the SAP 440 intersects with the stream of the melt-blown fibers or filaments 424 such that the SAP 440 impacts with the melt-blown fibers or filaments 424 and at least some of the SAP 440 is captured within the network of melt-blown fibers or filaments 424, forming a melt-blown composite 444. The melt-blown composite 444 includes a nonwoven web formed of the melt-blown fibers or filaments 424 and the SAP 440 mixed therein.

[0053] In some embodiments, the SAP 440 is held in a hopper of the SAP applicator 438 and is picked-up by an air stream via a venturi device. The SAP 440 is then carried by the air stream into a separate hot air stream that is carrying the melt-blown fibers or filaments 424. That is, the air stream containing the SAP 440 intersects with an air stream carrying the melt-blown fibers or filaments 424. The SAP 440 can be added into the hot air stream that is carrying the melt-blown fibers 424 just after (downstream) the melt-blown fibers or filaments 424 are extruded from the extruder of the melt-blown fiber applicator 402. As described in reference to FIG. 3, the SAP applicator 438 can be a venturi device that includes a hopper or otherATTY DOCKET: DSGI-1015WOcontainer that contains the SAP 440. An airstream can be fed through the venturi device, and suction from the venturi device forces the SAP 440 to exit the hopper and be deposited into the path of the melt-blown fibers or filaments 424 as the hot melt-blown fibers or filaments 424 exit the die head and move toward the conveyor belt 446.

[0054] The angle of impact 439, at which the steam of SAP 440 exiting the SAP applicator 438 impacts the stream of melt-blown fibers or filaments 424 exiting the die head of the melt-blown applicator 402 affects the mixing of the melt-blown fibers or filaments 424 with the SAP 440. In some embodiments, the angle of impact 439 is controlled to affect the content and structure of the resultant melt-blown composite 444. Controlling the angel of impact 439 (z.e., relative angle of the two streams) can facilitate reducing or preventing loss of SAP 440 upon impact of the SAP 440 with the melt-blown fibers or filaments 424. That is, the angle of impact 439 can affect whether and how much of the SAP 440 is captured within the network of the melt-blown fibers or filaments 424 as opposed to how much of the SAP 440 is deflected by the network of the melt-blown fibers or filaments 424 and / or passes entirely through the network of the melt-blown fibers or filaments 424. In some embodiments, the angle of impact 439 is adjusted to prevent or reduce the amount of loose SAP in the final composite product. As used here, “loose SAP” refers to SAP 440 that is not adhered to the melt-blown fibers or filaments 424 and is, thus, capable of movement relative to the nonwoven web of the melt-blown fibers or filaments 424. The angle of impact 439 can be any angle depending on the desired outcome. In some embodiments, the angle of impact 439 ranges from 80 degrees to 100 degrees or from 85 degrees to 95 degrees, or 90 degrees, or any discrete value or range therebetween. Applicants have unexpectedly and surprisingly found that an angle of impact 439 that is 90 degrees results in better mixing between the SAP 440 and the melt-blown fibers or filaments 424 and reduces the loss of SAP 440. The angle of impact 439 is described further with reference to FIG. 9C elsewhere herein.

[0055] The amount of the SAP 440 that is applied onto the network (web) of the melt-blown fibers or filaments 424 can be controlled by various gravimetric and / or volumetric methods. In some embodiments, all or substantially all of the SAP 440 is mixed into the melt-blown fibers or filaments 424 with no or minimal loss of the SAP 440.

[0056] The melt-blown applicator 402 and the SAP applicator 438 can be positioned and arranged such that the SAP 440 impacts the melt-blown fibers or filaments 424 while the melt-blown fibers or filaments 424 are in an at least partially melted and tacky state. For example, upon exit from the extruder of the melt-blown applicator 402, the melt-blown fibers or filaments 424 are in an at least partially molten state and are, thus, tacky. Once the melt-ATTY DOCKET: DSGI-1015WOblown fibers or filaments 424 exit the melt-blown applicator 402 and proceed toward the conveyer belt 446, the melt-blown fibers or filaments 424 begin to cool and become less tacky. Thus, the SAP applicator 438 can be positioned sufficiently close to the extrusion point of the melt-blown fibers or filaments 424 that the melt-blown fibers or filaments 424 are still tacky. Due to the melted and tacky state of the melt-blown fibers or filaments 424, the SAP 440 will stick and / or adhere to the melt-blown fibers or filaments 424 upon impact therewith, even without use of any adhesives. Upon subsequent cooling of the melt-blown fibers or filaments 424, the SAP 440 remain at least partially adhered to the melt-blown fibers or filaments 424 due to the adhesion that occurs upon impact.

[0057] The melt-blown fibers or filaments 424 and, subsequently the melt-blown composite 444, move toward a surface for deposition, with the SAP 440 impacting with the melt-blown fibers or filaments 424 prior to deposition on the surface. In some embodiments, the melt-blown fibers or filaments 424, and subsequently the melt-blown composite 444, fall toward the surface via gravity. The melt-blown composite 444 is deposited onto a collection surface, here shown as the surface of a substrate nonwoven 450 on a conveyer belt 446 of a belt conveyer system 448. The belt conveyer system 448 includes a plurality of rollers 454 and a drive roller 456 to drive the conveyer belt 446 in a clockwise direction to define process direction 458 of belt 446.

[0058] In some embodiments, the formation of the melt-blown composite 444 completes the process. In other embodiments, as shown in FIG. 4, the process includes incorporating the melt-blown composite 444 with one or more nonwoven sheets to form an absorbent composite that contains the melt-blown composite 444. For example, in some embodiments the substrate nonwoven 450 (optional) is fed onto the conveyer belt 446 by a roller 452 such that the melt-blown composite 444 is deposited onto the substrate nonwoven 450 rather than directly onto the conveyer belt 446, and such that the substrate nonwoven 450 is positioned between the conveyer belt 446 and the melt-blown composite 444. The combination of the substrate nonwoven 450 and the melt-blown composite 444 is conveyed in process direction 458 for receipt of a cover nonwoven 460. Cover nonwoven 460 is fed from roller 462 to application roller 464. Application roller 464 applies the cover nonwoven 460 onto the melt-blown composite 444 such that the melt-blown composite 444 is positioned between the conveyer belt 446 and the cover nonwoven 460. In embodiments that include the substrate nonwoven 450, the melt-blown composite 444 is sandwiched between the cover nonwoven 460 and the substrate nonwoven 450.ATTY DOCKET: DSGI-1015WO

[0059] The system 400 includes a hot melt applicator 466 positioned between the roller 462 and the application roller 464. The hot melt applicator 466 deposits a hot melt adhesive (HMA) onto the cover nonwoven 460 prior to combining the cover nonwoven 460 with the melt-blown composite 444, providing for adhesion between the cover nonwoven 460 and melt-blown composite 444. The combination of the melt-blown composite 444 and the cover nonwoven 460, and optionally the substrate nonwoven 450, forms an absorbent composite 468. The absorbent composite 468 is collected onto a collection roller 470. The absorbent composite 468 can then, optionally, be incorporated into a disposable absorbent article, such as a diaper. While a hot melt applicator is used in the embodiment of FIG. 4, adhesion via hotmelt is optional. In some embodiments, lamination of the layers of the nonwoven composite with the substrate and / or cover nonwovens is achieved via ultrasonic bonding or thermal bonding. Residual heat and tackiness of the melt-blown fibers or filaments 424 in the melt-blown composite 444 provides at least some adhesion between the layers.

[0060] The conveyor belt 446 provides a surface onto which the output (extrudate) of the melt-blown applicator 402 is directed. That is, streams of hot melted strands of melt-blown fiber or filaments s 424 are collected on a surface of the conveyor belt 446 (or a surface of the substrate nonwoven 450) where the melt-blown fibers or filaments 424 rapidly cool to form polymer filaments. The cooled filaments of melt-blown fibers or filaments 424 form a nonwoven web of the melt-blown fibers or filaments 424. The speed at which the conveyor belt 446 draws the nonwoven web away from the melt-blown applicator 402 and away from the point of initial contact between the melt-blown fibers or filaments 424 in process direction 458, combined with the speed of the output of the melt-blown fibers or filaments 424 from the melt-blown applicator 402, at least partially determines a basis weight of the resultant nonwoven web portion fo the absorbent composite 468.Multiple Melt-Blown Applicators

[0061] In some embodiments, the systems and processes disclosed herein include more than one melt-blown applicator. The melt-blown applicators can be arranged in series such that the output (melt-blown fibers) of one of the melt-blown applicators is deposited above the output of the other of the melt-blown applicators.

[0062] FIG. 5 depicts a portion of a system for forming an absorbent composite using more than one melt-blown applicator in accordance with embodiments of the present disclosure. The system 500 is substantially the same as system 400 of FIG. 4, with like reference numerals indicating like elements. The primary difference between system 500 and system 400 is that system 500 includes two melt-blow fiber applicators instead of one, including the melt-blownATTY DOCKET: DSGI-1015WOfiber applicator 402 (as in FIG. 4) and the additional melt-blown fiber applicator 502. In system 500, the melt-blown fiber applicator 502 is positioned downstream of the melt-blown fiber applicator 402 and deposits melt-blown fibers or filaments 524 on top of the melt-blown composite 444, forming melt-blown composite 544. The melt-blown fibers or filaments 424 and 524 and the SAP 440 are combined to form the melt-blown composite 544. The melt-blown composite 544 is substantially similar to the melt-blown composite 444, but includes two layers of the melt-blown fibers or filaments rather than one layer. In some embodiments, the melt-blown composite 544 includes a layer of SAP 440 intermixed with both layers of melt-blown fibers or filaments 424 and 524. The melt-blown composite 544 is combined with the cover nonwoven 460 and optional substrate nonwoven 450 to form an absorbent composite which can, optionally, be incorporated into a disposable absorbent article, such as a diaper.

[0063] In some embodiments, the melt-blown fibers or filaments 424 are composed of the same material as the melt-blown fibers or filaments 525. For example, both melt-blown fibers or filaments 424 and melt-blown fibers or filaments 524 can be polypropylene fibers. In other embodiments, the melt-blown fibers or filaments 424 are composed of a different material than the melt-blown fibers or filaments 524. For example, the melt-blown fibers 424 can be polypropylene fibers and melt-blown fibers or filaments 524 can be TPU fibers or filaments. The entirety of system 500 is not shown; however, a remainder of the system 500 upstream of melt-blown fiber applicator 402 and downstream of melt-blown fiber applicator 502 can be the same or substantially similar to that shown in FIG. 4.Multiple SAP Applicators

[0064] In some embodiments, the systems and processes disclosed herein include more than one melt-blown applicator and / or more than one SAP applicator. The SAP applicators can be arranged in series such that the output (SAP) of one of the SAP applicators is deposited above the output of the other of the SAP applicators.

[0065] FIG. 6 depicts a system for forming an absorbent composite in accordance with embodiments of the present disclosure. System 600 is substantially the same as systems 400 and 500 of FIGS. 4 and 5, respectively, with like reference numerals indicating like elements. The difference between system 600 and system 500 is that system 600 includes two SAP applicators instead of one, and three melt-blow fiber applicators instead of two. System 600 includes SAP applicator 438 (as in FIGS. 4 and 5) and an additional SAP applicator 638 upstream of the SAP applicator 438. System 600 includes melt-blown fiber applicator 502 (as in FIG. 5) positioned downstream of SAP applicators 438 and 638. System 600 includes melt-blown fiber applicator 402 (as in FIGS. 4 and 5) intermediate both SAP applicators 438 andATTY DOCKET: DSGI-1015WO638. System 600 includes additional melt-blown fiber applicator 602 positioned upstream of melt-blown fiber applicators 402 and 502 and SAP applicator or filaments s 438 and 638. In the system 600, the melt-blown fiber applicator 602 deposits melt-blown fibers 624 onto the belt 446 (or the substrate nonwoven 450). The two SAP applicators 438 and 638 impart streams of SAP 440 and 640, respectively, onto the melt-blown fibers or filaments 424, which is then deposited onto the melt-blown fibers or filaments 624. The melt-blown fiber applicator 502 then deposits melt-blown fibers or filaments 525 onto the combination of the melt-blown fibers or filaments 624, melt-blown fibers or filaments 424, SAP 440 and SAP 640, forming melt-blown composite 644. The melt-blown composite 644 is substantially similar to the melt-blown composite 544, but includes three layers of the melt-blown fibers or filaments rather than two layers and two layers of SAP rather than one layer. In some embodiments, the melt-blown composite 644 includes a layer of SAP 640 intermixed with both layers of melt-blown fibers or filaments 524 and 624, and another layer of SAP 440 intermixed with layers of melt-blown fibers 624 and or filaments 424. The melt-blown composite 644 is combined with the cover nonwoven 460 and optional substrate nonwoven 450 to form an absorbent composite which can, optionally, be incorporated into a disposable absorbent article, such as a diaper.

[0066] In some embodiments, the melt-blown fibers or filaments 424, 524, and 624 are each composed of the same material. In other embodiments, one or more of the melt-blown fibers or filaments 424, 524, and 624 are composed of a different material than the other of the melt-blown fibers or filaments 424, 524, and 625. For example, the melt-blown fibers or filaments 424 can be polypropylene fibers or filaments without an elastomer, the melt-blown fibers or filaments 524 can be TPU fibers or filaments, and the melt-blown fibers or filaments 624 can be polypropylene fibers or filaments mixed with an elastomer.

[0067] In some embodiments, the SAP 440 and SAP 640 are composed of the same material and have the same properties. For example, both SAP 440 and SAP 640 can be of the same material composition and the same average particle size. In other embodiments, the SAP 440 and SAP 640 are composed of different materials. For example, SAP 440 can be of a first material composition and / or average particle size, and SAP 640 can be of a second, different material composition and / or different average particle size.

[0068] The entirety of system 600 is not shown for; however, a remainder of the system 600 upstream of melt-blown fiber applicator 602 and downstream of melt-blown fiber applicator 502 can be the same or substantially similar to that shown in FIGS. 4 and 5.Additive ApplicatorsATTY DOCKET: DSGI-1015WO

[0069] Some embodiments of the systems and processes disclosed herein include one or more additive applicators used to incorporate additional particles and / or fibers into the absorbent composites. In some embodiments, the additives can be provided onto the melt-blown fibers using a second venturi device that functions the same or similar as that described herein with reference to the SAP applicator. The present disclosure is not limited to use of a venturi device, and may include other systems or devices for conveying fibers, particles, or SAP into an airstream. In some embodiments, the additives are mixed with the SAP and incorporated with the melt-blown fibers along with the SAP.

[0070] In some embodiments, the additives disclosed in one or more of EP3861970A1, EP4014937A1, US2015 / 0190541 Al, EP1503812B1, and EP1991729B2 are used as additives in the composites disclosed herein. Each of EP3861970A1, EP4014937A1, US2015 / 0190541A1, EP1503812B1, and EP1991729B2 are incorporated herein by reference for the purposes of background disclosure in respect to additives that may be used in the composites disclosed herein. Some exemplary additives suitable for use herein include polylactic acid (PLA) short fibers, polyethylene terephthalate (PET) hollow fibers, calcium carbonate fibers, omya fibers, perlite, pumice, zeolite, chitosan, collagen, PLA, polypropylene (PP), polyurethane (PU), polypropylene / polyethylene (PP / PE) bicomponent fibers, granules, and thermally expandable microspheres. For example, sheets of PLA, PP / PE bicomponent fibers, and / or PET can be used for shaping channels for capillary flow. An air-through PET distribution layer with open pores or a PLA spunbond can be used as a capillary accelerating sheet within the absorbent core. Some embodiments of the composite include a conformed web of hydrophilic fibrillated nanofibers and SAP. Acidic or basic water absorbent resin particles can be added to control pH. Some embodiments of the composite include wood pulp and a PP / PE bicomponent co-formed web, without granules.

[0071] FIG. 7 depicts a system for forming an absorbent composite in accordance with embodiments of the present disclosure. System 700 is substantially the same as systems 400, 500 and 600 of FIGS. 4, 5, and 6, respectively, with like reference numerals indicating like elements. One difference between system 700 and system 600 is that system 700 includes an additive applicator 772 for incorporation of one or more additives 774 into the melt-blown composite 744. In the embodiment of FIG. 7, the SAP applicator 638 imparts a stream of SAP 640 onto the melt-blown fibers 624 exiting the melt-blown applicator 602. The combination of the melt-blown fibers 624 and the SAP 640 is deposited onto the belt 446 (or the substrate nonwoven 450). The additives applicator 772 imparts a stream of additives 774 onto the melt-blown fibers 424 exiting the melt-blown applicator 402. The combinations of the melt-blownATTY DOCKET: DSGI-1015WOstream 424 and additives 774 is deposited onto the combination of the blown fibers 624 and the SAP 640. The SAP applicator 438 imparts a stream of SAP 440 onto the melt-blown fibers 525 exiting the melt-blown applicator 502. The combination of the melt-blown fibers 525 and SAP 440 is deposited onto the combination of the melt blown fibers 424 and 624, SAP 640, and additives 774, forming the melt-blown composite 744. The melt-blown composite 744 is substantially similar to the melt-blown composite 644, but includes additives 774. The melt-blown composite 744 is combined with the cover nonwoven 460 and optional substrate nonwoven 450 to form an absorbent composite which can, optionally, be incorporated into a disposable absorbent article, such as a diaper.

[0072] The additives 774 can be added to impart functionality to the absorbent composite 768. For example, in some embodiments the additives 774 include fibers (e.g., staple fibers) that promote fluid flow, absorption, wettability, or combinations thereof. The additive fibers 774 can include cellulose acetate fibers, viscose fibers, bicomponent fibers, cotton fibers, bamboo fibers, hemp fibers, polylactic acid (PLA) fibers, or combinations thereof. In some embodiments, the additives 774 can include micro-fibrillated cellulose (MFC). The additives 774 can include spacing particles to create gaps and voids in the absorbent composite 768 for fluid flow. The additives 774 can include water / urine soluble granules, such as surfactants or polyvinyl alcohol (PVA).

[0073] The melt-blown fibers disclosed herein can include one or more thermoplastic polymers, such as polypropylene and / or polyurethane. In some embodiments, the melt-blown fibers disclosed herein include one or more elastomers. Prior to being melted, the material used to from the melt-blown fibers can be in pellet form. The additives can include wetting agents, flow promoters. In some embodiments, the additives include fibers and / r particles.

[0074] While the additives are shown as being incorporated via a separate applicator in FIG. 7, in other embodiments additives are mixed with the SAP and the SAP and additives are incorporated into the melt-blown fibers together. In some embodiments, additives that can be subjected to the melt-blowing process are mixed with the pellets of polymer prior to extrusion and are subjected to melt-blowing extrusion along with the polymer.

[0075] The entirety of system 700 is not shown for; however, a remainder of the system 700 upstream of melt-blown fiber applicator 602 and downstream of melt-blown fiber applicator 502 can be the same or substantially similar to that shown in FIGS. 4, 5 and 6.Integration of SAP into the Melt-Blown Fibers

[0076] Having generally described, with reference to FIGS. 4-7, the systems and processes for the formation of the composite materials disclosed herein, the integration of theATTY DOCKET: DSGI-1015WOSAP into the melt-blown fibers is now described in more detail with reference to FIGS. 9A-9C. Integrating the SAP with (and partially into) the melt-blown fibers includes intersecting a stream of SAP with a stream of melt-blown fibers while the SAP and melt-blown fibers are passing through a portion of space (e.g., a deposition zone). For example, the SAP and melt-blown fibers can be passing through the air when the streams intersect. The intersection of the streams results in the capturing of at least some of the SAP within the network of the melt-blown fibers. With the melt-blown fibers in a tacky state, at least partially molten or above the glass transition temperature, the SAP adheres to the tacking melt-blown fibers, which subsequently cool, stabilizing the adherence of the SAP with the melt-blown fibers.

[0077] FIGS. 9A-9C depict systems and processes in accordance with embodiments of the present disclosure showing how the SAP is co-deposited and incorporated into the melt-blown fibers. With reference to FIG. 9A, system 901 includes melt-blown applicator 10, SAP applicator 20, and conveyer 30. The melt-blown applicator 10 includes a melt-blown fiber extruder with a plurality of melt blown nozzles 11. The melt-blown applicator 10 extrudes a hot air stream of melt-blown filaments 12 through the nozzles 11. The filaments 12 exit the applicator 10 in direction 13, towards the conveyer belt 31 of conveyer 30. The filaments 12 travel along direction 13 in a hot air stream. In some embodiments, the plurality of filaments 12 are, generally, spaced-apart and form a curtain of filaments that is directed toward the belt 31. The SAP applicator 20 is positioned to direct a hot air stream of SAP 21 toward the hot air stream of melt-blown filaments 12. The hot air stream of SAP 21 is directed toward the filaments in direction 15. The SAP 21 impacts the melt-blown fibers 12 at a position that is below the nozzles 11 and above the belt 31.

[0078] The angle of impact X between the stream of SAP 21 and the stream of melt-blown fibers 12 (i.e., the angle between direction 15 and direction 13) is shown in FIGS. 9A and 9C. In some embodiments, the angle of impact X ranges from 45 degrees to 135 degrees, from 60 degrees to 120 degrees, from 80 degrees to 100 degrees, from 85 degrees to 95 degrees, or any range or discrete value therebetween. In some embodiments, angle of impact X is 90 degrees. In some exemplary embodiments, the angle of impact X is from 60° to 80°. Without being bound by theory, an angle of impact X that is sufficiently greater than 90° may be undesirable as the stream of SAP 21 may impart an opposing directional force onto the stream of melt-blown fibers 12.

[0079] As shown in FIG. 9B, the stream of SAP 21 impacts a first side 19a of the stream of melt-blown fibers 12. The SAP 21 penetrates into the curtain or mat of the melt-blown fibers 12 toward a second side 19b. The stream of SAP 21 includes multiple SAP of variousATTY DOCKET: DSGI-1015WOparticles sizes. The SAP 21b of smaller particle size penetrates deeper into the melt-blown fibers 12 toward the second side 19b in comparison to the SAP 21a of larger particle size, which is captured within the network of melt-blown fibers 12 closer to the first side 19a, resulting in a particle size gradient in the melt-blown composite 40.

[0080] After impact of the SAP 21 with the melt-blown fibers 12, the thusly formed melt-blown composite 40 is deposited onto the belt 31 which moves the composite 40 in process direction 41. The speed of the belt 31 can be varied to affect the basis weight of the composite 40.

[0081] System 901 includes an optional additive applicator 50. The additive applicator 50 is positioned to supply a stream of additives 51 onto the melt-blown fibers 12. As shown, the additive applicator 50 is positioned to supply the stream of additives 51 onto the melt-blown fibers 12 downstream (i.e., after) of where the SAP 21 is supplied to the melt-blown fibers 12. Thus, the additives 51 impact a combination of the SAP 21 and the melt-blown fibers 12. In other embodiments, the additives can be supplied to the melt-blown fibers simultaneously (e.g., the SAP and additives can be mixed together prior to impacting the melt-blown fibers). In further embodiments, the additives can be supplied to the melt-blown fibers upstream (i.e., before) of where the SAP is supplied to the melt-blown fibers. In still further embodiments, the additives can be supplied to a different web of melt-blown fibers that is subsequently combined with the web of melt-blown fibers on which the SAP is supplied (e.g., as shown in FIG. 7). In some embodiments, the systems disclosed herein do not include an additives applicator.

[0082] The height of the position where the melt-blown fibers 12 exit the nozzles 11 above the conveyer belt 31, distance 53, can be minimized to be as small as practicable such that the melt-blown fibers 12 do not cool too much prior to impacting the conveyor belt 31 or other cooling surface. The distance 53 is sufficient such that the SAP applicator 20 and other applicators (e.g., additives applicator 50) have enough space to impact the SAP 21 and optional additives 51 with the melt-blown fibers 12 prior to the melt-blown fibers 12 impacting the conveyer belt 31 or other cooling surface. In some exemplary applications, height 53 is from 40 to 80 cm. However, height 53 can be smaller than 40 cm or larger than 80 cm.

[0083] The distance between the end of the SAP applicator 20 nozzle and the stream of melt-blown fibers 12, distance 61, can be controlled. In some exemplary applications, the distance 61 is from 4 to 8 cm. If the distance 61 is too high, then the angle of impact X may undesirably change as the stream of SAP 21 changes direction. For example, if the distanceATTY DOCKET: DSGI-1015WO61 is too great then the direction 15 may not remain linear as the stream of SAP 21 arcs downwards due to gravitational force.

[0084] The distance 71 between the position where the melt-blown fibers 12 exit the nozzles 11 and the SAP 21 impacts the fibers 12 can be controlled such that the melt-blown fibers 12 do not cool too much prior to impacting with the SAP 21.

[0085] In some embodiments, the throughput rate of the melt-blown fiber 12 from the applicator 10 and of the throughput rate of SAP 21 from the applicator 20 are each sufficient to form an absorbent core on a conventional diaper line running at normal production speeds. For example, the throughput rate of the melt-blown fiber 12 can be sufficient to produce 0.5 to 2 kg of melt-blown fibers 12 per minute. The throughput rate of the SAP 21 can be sufficient to deliver from 9.6 to 38.6 kg of SAP 21 per minute. The delivery rate (throughput) can be reduced if multiple MB and SAP applicators are used. For example, in a process with two MB extruders, the MB throughput requirement can be halved per head.

[0086] In some embodiments, the SAP 21 is at ambient temperature when directed toward the melt-blown fibers 12. When exiting the extruder and upon impact with the SAP 21, the polymer of the melt-blown fibers 12 can be from 150°C to 250°C, or from 160°C to 240°C, or from 170°C to 230°C, or from 180°C to 220°C, or from 190°C to 210°C, or about 200°C, or any range or discrete value therebetween. For example, in embodiments where the polymer is polypropylene, the polymer of the melt-blown fibers 12, when exiting the extruder and upon impact with the SAP 21, may be about 230°C. In embodiments where the polymer is thermoplastic polyurethane, the polymer of the melt-blown fibers 12, when exiting the extruder and upon impact with the SAP 21 , may be about 200°C. The temperature of the polymer is not limited to these values and may vary depending on, for example, the melting and / or glass transition temperature of the polymer. The temperature of the melt-blowing process has an impact on the fiber formation and the quality of the fibers formed.

[0087] Upon impact of the SAP 21 with the fibers 12, the SAP 21 and fibers 12 may be subject to turbulent mixing to incorporate the SAP 21 into the fibers 12. For example, the fibers 12 travel downward in a first hot air stream toward the conveyer belt 31 and the SAP 21 travels in a second hot air stream toward the fibers 12. Upon impact of these two hot air streams, the hot air streams turbulently mix together. This turbulent mixing of the hot air streams facilitates penetration of the SAP 21 deeper into the fibers 12. Additionally, this turbulent mixing of the two hot air streams facilities movement of at least some of the fibers 12, opening the network of the fibers 12 and providing additional void space for the SAP 21 to reside within in the network of the fibers 12. In some embodiments the size, shape, and number of SAP 21ATTY DOCKET: DSGI-1015WOparticles and any additives 51 affects the mixing (e.g., the degree of turbulence of the mixing). For example, less spherical and / or regular shaped and / or larger particles may induce more turbulence than more spherical and / or regular shaped and / or smaller particles. The SAP 21 (and additives 51) may impact one side of the mat of melt-blown fibers, as shown in FIG. 4, or both sides of the mat of melt-blown fibers as shown in FIG. 6.

[0088] As the fibers 12 are at least partially molten (e.g., above the glass transition temperature), the fibers 12 are in a soft, viscous state such that the tackiness of the polymer enables relatively quick, intimate contact and bonding with the SAP 21 such that the SPA 21 adheres or bonds with the fibers 12 via tack. The relatively sticky, soft, viscoelastic state of the polymer that the fibers 12 include facilitates relatively rapid formation of bonds (e.g., via van der Waals interactions, wetting, and viscoelastic deformation) without necessarily requiring chemical reaction bonding or curing.

[0089] Thus, the processes disclosed herein are used to form SAP-based, melt-blown composites 40 by melt-blowing a polymer to from a filament network of melt-blown fibers 12 of the polymer. As the melt-blown fibers 12 move (e.g., fall via gravity) toward the conveyer belt 31 in a hot air stream, the SAP 21 is dynamically integrated into the filament network of the melt-blown fibers 12. The SAP 21 is carried in another hot air stream toward the fibers 12. For example, the SAP can be sprayed from a nozzle or otherwise forced toward the fibers 12. The SAP 21 impacts with a firs die 19a of the filament network of the melt-blown fibers 12 such that at least a portion of the SAP 21 embeds into the network of the melt-blown fibers 12. The impact of the SAP 21 with the melt-blown fibers 12 causes the SAP 21 to be forced into the network of the melt-blown fibers 12 at a depth between the first surface 19a and second surface 19b of the network of the melt-blown fibers 12. The network of the melt-blown fibers 12 has void spaces between the fibers to accept the SAP 21. Additionally, the impact of the SAP 21 with the network of the melt-blown fibers 12 causes at least portions of the network of the melt-blown fibers 12 to open up, expanding the size of the void spaces and providing more void space for the SAP 21. As the SAP 21 impacts the network of the melt-blown fibers 12 at the first surface 19a, the opening of the network of the melt-blown fibers 12 is more substantial at and proximate the first surface 19a than at and proximate the second surface, such that the network of the melt-blown fibers 12 exhibits a gradient void volume and bulk density, with the void volume of the network of the melt-blown fibers 12 being greater at the first surface 19a than the second surface 19b, and with the bulk density being greater at the second surface 19b than the first surface 19a.ATTY DOCKET: DSGI-1015WO

[0090] The impact of the SAP 21 with the network of the melt-blown fibers 12 results in at least a portion of the melt-blown fibers 12 to extend about the SAP 21 particles, forming a scaffolding structure that facilitates retention of the SAP 21 within the filament network of the melt-blown fibers 12. That is, the scaffolding structure is the portion of the network of the melt-blown fibers 12 that is at and closer to the first surface 19a, and that has a lower bulk density and higher void volume. This lower bulk density and higher void volume portion of the network of the melt-blown fibers 12 include fibers 12 that extend about and partially entangle at least some of the SAP 21 particles. The scaffolding structure, thus, functions to entrap and retain at least some of the SAP 21. The increased void volume of the scaffolding structure provides for void space that allows the SAP 21 particles to be more spaced about and to swell more readily upon insult without restriction from other SAP particles and / or fibers. Additionally, the open and, lower bulk density, fibers of the scaffold structure function as wicking paths for insult to be carried to the SAP 21.

[0091] In some embodiments, the process of making the composites is an online process, where the composites are made in-line with a diaper manufacturing process such that the composite 40 is fed, as an absorbent core, directly into the diaper manufacturing process for combination with the other components of a diaper (e.g., a chassis). In other embodiments, the process of making the composites is an offline process, where the composites are made separately from a diaper manufacturing process such that the composite 40 is collected for later use as an absorbent core and is, thus, indirectly combined with a diaper manufacturing process for combination with the other components of a diaper. In online processes, the curtain of fibers 12 from the extruder 10 can be, for example, from 80 mm to 120 mm wide (e.g., from side 19a to side 19b). In offline processes, the web if fibers 12 can be wider than this, such as from 2,000 to 3,500 mm wide, and the composite 40 an be collected on a roll for later use. In the offline process, at use, the composite can be unrolled and cut into the desired sizes.Single Melt-Blown Layer Composites

[0092] FIGS. 8 A and 8B depict an exemplary melt-blown composite 844a. Melt-blown composite 844a includes a single layer of melt-blown fibers 824a and SAP 840a intermixed therewith. The SAP 840a is at least partially embedded into and / or entangled by the melt-blown fibers 824a. In some embodiments, the melt-blown composite 844a has density gradient of melt-blown fibers 824a. For example, melt-blown composite 844a has a first surface 876 and a second, opposing surface 878. The density of the melt-blown fibers 824a, on average, decreases when moving from the second surface 878 to the first surface 876. In some embodiments, the melt-blown composite 844a has particle size gradient of SAP 840a. ForATTY DOCKET: DSGI-1015WOexample, the particle size of SAP 840a, on average, increases when moving from the second surface 878 to the first surface 876. The melt-blown composite 844a is exemplary of a composite that can be made with the system 400 shown in FIG. 4.

[0093] The lower density region of the layer of melt-blown fibers 824a forms a scaffolding structure 823 of melt-blown composite 844a. The scaffolding structure 823 is a region of the melt-blown composite 844a in which the melt-blown fibers 824a have greater void volume 827 between the fibers 824a, providing interstitial space between the fibers 824a in which the particles of SAP 840 reside. As can be seen in FIG. 8B, the smaller particles of SAP 840b are positioned closer to the second surface 878 and the larger particles of SAP 840a are positioned closer to the first surface 876, forming the gradient distribution of the SAP 840 in the direction for first surface 876 to second surface 878. In some embodiments, prior to impact with the SAP 840, the melt-blown fibers 824a do not exhibit a gradience in void volume or bulk density and do not have the scaffolding structure 823, and the impact with the SAP 840 forces some of the fibers 824a at and proximate the first surface 876 to open up forming the scaffolding structure 823, increasing the void volume, and decreasing the bulk density at and proximate the first surface 876.

[0094] In the scaffolding structure 823, a network of the melt-blown fibers 824a extends about the particles of SAP 840 to stabilize and retain the SAP 840 within the filament network of the melt-blown fibers 824a. In use, the first surface 876 can be the body side surface (or closer to the body side than the second surface 878) and function to receive and distribute liquid insult. The void volume of the scaffolding structure 823 at the first surface 876 allows the SAP 840 to swell unrestricted (or at least less restricted) as the SAP 840 is spaced apart from the fibers 824a and other particles of the SAP 840. Additionally, the open network of fibers 824a that form the scaffolding structure 823 function as capillary paths for fluid to be carried from the first surface 876 deeper into the melt-blown composite 844a toward the second surface 878 for absorptions by the small particles of SAP 840b. Thus, the scaffolding structure 823 enhances the absorption efficiency of the melt-blown composite 844a.

[0095] The higher density region of the layer of melt-blown fibers 824a forms a retention structure 825 of melt-blown composite 844a. The retention structure 825 is a region of the melt-blown composite 844a in which the melt-blown fibers 824a have less void volume between the fibers 824a, providing less interstitial space between the fibers 824a in which the particles of SAP 840 reside. In some embodiments, upon impact with the SAP 840, the melt-blown fibers 824a of the retention structure 825 do not open up (or open less than at the scaffolding structure 823) such that the retention structure 825 functions to reduce or preventATTY DOCKET: DSGI-1015WOpassage of the SAP 840 entirely through the melt-blown fibers 824a and past the second surface 878.

[0096] FIG. 8G is a top view of the melt-blown composite 844a, looking at the scaffolding structure 823 at the first surface 876. At least some of the melt-blown fibers 824a extend about, around, along, and / or over a top of the SAP 840a and 840b. The void space 827 is interstitial space between particles of the SAP 840a and 840b. While the melt-blown fibers 824a occupy a portion of the void space 827, the melt-blown fibers 824a are sufficiently elastic that, when the SAP 840a and 840b swells, the melt-blown fibers 824a elastically move and / or deform to accommodate the swelling of the SAP 840a and 840b. In some exemplary embodiments, the SAP particles will be interlaced with hundreds of individual filaments of fibers 824a about all sides of the particle.Dual Melt-Blown Layer Composites

[0097] FIGS. 8C and 8D depict an exemplary melt-blown composite 844b. Melt-blown composite 844b includes melt-blown fibers 824a, melt-blown fibers 824b, and SAP 840a intermixed with both the melt-blown fibers 824a and 824b in a central region 880. The SAP 840a is at least partially embedded into and / or entangled by the fibers of each of the melt-blown fibers 824a and 824b. In some embodiments, the melt-blown composite 844b has density gradient of melt-blown fibers 824a and 824b. The density of the melt-blown fibers 824a, on average, decreases when moving from the second surface 868 to the central region 880. The density of the melt-blown fibers 824b, on average, decreases when moving from the first surface 876 to the central region 880. In some embodiments, the melt-blown composite 844b has particle size gradient of SAP 840a. For example, the particle size of SAP 840a, on average, increases when moving from the second surface 868 to the first surface 876. The melt-blown composite 844b is exemplary of a composite that can be made with the system 500 shown in FIG. 5.

[0098] The melt-blown composite 844b has a scaffolding structure 823 sandwiched between two retention structures 825a and 825b. The retention structures 825a and 825b have densities sufficient to retain the SAP 840 within the composite 844b, with the smaller sized SAP 840b positioned closer to the retention structure 825b and the larger sized SAP 840a positioned closer to the retention structure 825a.Triple Melt-Blown Layer and Dual SAP Layer Composites

[0099] FIGS. 8E and 8F depict an exemplary melt-blown composite 844c. Melt-blown composite 844c includes melt-blown fibers 824a, melt-blown fibers 824b, melt-blown fibers 824c, SAP 840a intermixed with melt-blown fibers 824a and 824b in a first central region 880a,ATTY DOCKET: DSGI-1015WOand SAP 840b intermixed with melt-blown fibers 824b and 824c in a second central region 880b. The layer of SAP 840a is at least partially embedded into and / or entangled by the fibers of melt-blown fibers 824a and 824b. The SAP 840b is at least partially embedded into and / or entangled by the fibers of each of melt-blown fibers 824b and 824c. In some embodiments, the melt-blown composite 844b has density gradient of melt-blown fibers 824a, 824b, and 824c. The density of the melt-blown fibers 824a, on average, decreases when moving from the second surface 878 to the first central region 880a. The density of the melt-blown fibers 824c, on average, decreases when moving from the first surface 876 to the second central region 880b. In some embodiments, the melt-blown composite 844c has particle size gradient of SAP 840a and SAP 840b. For example, the particle size of SAP 840a, on average, increases when moving from the second surface 878 to the central region 880a, and the particle size of SAP 840b, on average, increases when moving from the first surface 876 to the central region 880b. The melt-blown composite 844c is exemplary of a composite that can be made with the system 600 shown in FIG. 6.[000100] The melt-blown composite 844c has a first scaffolding structure 823a sandwiched between retention structures 825a and 825b and a second scaffolding structure 823b sandwiched between retention structures 825b and 825c. The retention structures 825a-825c have densities sufficient to retain the SAP 840 within the composite 844c, with the smaller sized SAP 840b positioned closer to the retention structures 825a and 825c and the larger sized SAP 840a positioned closer to the retention structure 825b.[000101] The melt-blown composites disclosed herein can be used in absorbent cores for diapers, adult incontinence products, feminine hygiene products, absorbent pads, pet waist pads, and other products. In some embodiments, a stand-alone process for making rolls of the absorbent composites is provided, which can subsequently be slit, stored and transported for use in a diaper manufacturing process. In other embodiments, an online process of making the absorbent composites is provided wherein the absorbent composite process is integrated into a diaper manufacturing process (e.g., at the same manufacturing location).[000102] After forming the melt-blown composite, in the form of a nonwoven web of the melt-blown fibers contain SAP and, optionally, other additives, the composite nonwoven web can be subjected to additional, subsequent processing steps to form an absorbent composite. In some embodiments (e.g., depending on the nature of the manufacturing process, such as the line width and speed) the melt-blown composite is fed directly to a diaper manufacturing process. In other embodiments rolls of the melt-blown composite are formed that are subsequently slit and transported to a diaper manufacturing process. The melt-blownATTY DOCKET: DSGI-1015WOcomposite can be layered with other materials during or before incorporation into a diaper or other absorbent article. For example, and without limitation, the composite can be layered or otherwise combined with an ADL layer, a core wrap layer, a tissue layer, a backsheet, and / or a topsheet. The composite may be subjected to additional post-processing, such as slitting, perturbing, embossing, and / or creping.[000103] The melt-blown composites and processes of making the same, as described herein, have numerous benefits and advantages, including: the ability to produce the same or substantially similar product consistently; the minimization of waste (e.g., minimal SAP loss); the minimization of cost (e.g., reduced raw materials) as an absorbent composite can be formed from just superabsorbent and melt-blown polymer filaments without requiring adhesive to adhere the polymer and SAP; improved absorbent performance, as the nonwoven scaffold provided by the melt-blown fibers can be tailored to ensure that the superabsorbent particles can swell rapidly and easily due to the elastication of the filaments of melt-blown fibers; and the ability to tailor the wettability of the melt-blown fibers with suitable additives to ensure efficient fluid flow and wicking through the core.[000104] The properties of the melt-blown composites disclosed herein can be affected by, among other factors, the angle of impact of the SAP stream and melt-blown fibers stream, the layering arrangement of one or more layers of SAP and one or more layers of melt-blown fibers in the composite.Properties of the Composite Layers[000105] In some embodiments, each layer of melt blown fibers of the melt-blown composites herein, such as the layer of melt-blown fibers 824a, has a basis weight of from 10 to 50 g / m2, or from 15 to 45 g / m2, or from 18 to 30 g / m2, or from 20 to 25 g / m2, or any discrete value or range therebetween. Each layer of melt blown fibers, such as the layer of melt-blown fibers 824a, has a thickness, prior to deposition of SAP thereon, of from 0.05 mm to 0.50 mm, or from 0.07 mm to 0.40 mm, or from 0.1 mm to 0.30 mm, m2, or any discrete value or range therebetween.[000106] The SAP loading for each layer of melt blown fibers that contains SAP, such as the layer of melt-blown fibers 824a, ranges from 100 to 700 g / m2, or from 200 to 500 g / m2, or from 250 to 450 g / m2, or from 300 to 400 g / m2, or any discrete value or range therebetween. The layer of SAP particles can have a thickness of from 0.1 mm to 1 mm, or from 0.2 mm to 0.9 mm, or from 0.3 mm to 0.7 mm, or from 0.4 mm to 0.5 mm, or any discrete value or range therebetween. When composite material has more than one layer of SAP, such as is shown in FIG. 8E, each layer of SAP can have a SAP loading of from 100 to 325 g / m2, or from 125 toATTY DOCKET: DSGI-1015WO300 g / m2, or form 150 to 250 g / m2, or any discrete value or range therebetween. When composite material has more than one layer of SAP, such as is shown in FIG. 8E, each layer of SAP can have a thickness of from 0.1 to 0.5 mm, or from 0.15 to 0.45 mm, or from 0.2 to 0.4 mm, or any discrete value or range therebetween.[000107] The basis weight of the melt-blown composite can range from 200 to 800 g / m2, or from 268 to 480 g / m2, or from 284 to 660 g / m2, or from 302 to 678 g / m2, or from 300 to 700 g / m2, or from 400 to 600 g / m2, or any discrete value or range therebetween.[000108] The thickness of the melt-blown composite can range from 0.30 mm to 2.50 mm, or from 0.37 mm to 1.10 mm, or from 0.40 mm to 2.00 mm, or from 0.66 mm to 1.70 mm, or from 0.50 to 1.90 mm, or from 0.73 mm to 2.10 mm, or from 0.70 to 1.50 mm, or any discrete value or range therebetween.[000109] The density of the melt-blown composite can range from 300 to 800 kg / m3, or from 400 to 700 kg / m3, or from 500 to 600 kg / m3, or from 436 to 724 kg / m3, or from 388 to 430 kg / m3, or from 322 to 413 kg / m3, or any discrete value or range therebetween.[000110] For example, the exemplary melt-blown composite 844a of FIG. 8A can have a basis weight of from 268 to 480 g / m2, a thickness of from 0.37 to 1.1 mm, and a density of from 436 to 724 kg / m3. The exemplary melt-blown composite 844b of FIG. 8C can have a basis weight of from 284 to 660 g / m2, a thickness of from 0.66 to 1.7 mm, and a density of from 388 to 430 kg / m3. The exemplary melt-blown composite 844c of FIG. 8E can have a basis weight of from 302 to 678 g / m2, a thickness of from 0.73 to 2.1 mm, and a density of from 322 to 413 kg / m3.Melt-Blown Polypropylene[000111] In some embodiments, the melt-blown composites disclosed herein include a combination of SAP and melt-blown thermoplastic polypropylene (PP) filaments. The melt-blown PP filaments form a network or scaffold around the powder particles of SAP to capture and hold the SAP in place. The melt-blown PP fdaments can be treated or modified to reduce hydrophobicity and / or make the melt-blown PP filaments hydrophilic and wettable. Increasing the hydrophilicity and wettability of the melt-blown PP filaments promotes liquid flow from the surface of the melt-blown composite to the interior and the SAP particles therein, facilizing absorption when used in an absorbent composite.[000112] The SAP is capable of absorbing liquids without the filaments of PP blocking the ability of the SAP to expand and swell as a result of the absorption. That is, the melt-blown PP filaments do not restrict, or at least only minimally restrict, the swelling of the SAP. In some embodiments, to facilitate the accommodation of SAP swelling, elastomers areATTY DOCKET: DSGI-1015WOincorporated into the polypropylene to allow the melt-blown fibers to stretch and move as the SAP swells. The melt-blown PP filaments, even with the elastomer incorporated therein, can have sufficient strength and structural integrity to hold the SAP in place in both a wet state and dry state.[000113] The raw materials for the melt-blown composites disclosed herein can include superabsorbent polymer particles, such as Sandia IM930, BASF, and Nippon Shokubai; polypropylene, such as Vistamax PP6035G1 500MFR from Exon Mobil, and Moplen PP HP560z 1500MF from Lyondell Basell; elastomer, such as Vistamax 7050BF from Exxon Mobil, and Elastomer MD1648V from Kraton; wetting agents, such as Techsurf 15560 from Techmer, and CESATM-stat APK600 from Avient, rheology modifiers, such as Vistmaxx 8880 from Exxon Mobil; and optional substrate nonwovens, such as 15gsm spunbond PP for topsheet nonwoven, or lOgsm hydrophilic SMS for core wrap nonwoven, or 40-80gsm airthrough PET nonwoven for ADL.[000114] In some embodiments, the melt-blown composites disclosed herein include from 5 to 78 wt.%, or from 10 to 70 wt.%, or from 20 to 60 wt.%, or from 30 to 50 wt.% of the polypropylene or other polyolefin. The thermoplastic polyolefin forms the structure backbone of the melt-blown composites disclosed herein.[000115] While the polymer is described as being polypropylene in some of the examples discussed herein, in some embodiments the polymer includes polyethylene.[000116] In some embodiments, additives are incorporated into the melt-blown composites. For example, flow promoters (e.g., staple fibers, particles) can be added to enhance wicking, fluid flow and absorbency distribution within the melt-blown composite. Wettable staple fibers can be added to provide temporary storage of fluid prior to SAP activation and absorption of fluid by the SAP. Such embodiments can exhibit active passing of fluid from the flow promoter to the SAP particle.[000117] In some embodiments, the melt-blown composites disclosed herein include from 0 to 16 wt.%, or from 1 to 15 wt.%, or from 5 to 10 wt.% of a rheology modifier. The rheology modifier serves to modify the viscosity of the filaments during processing (e.g., during extrusion), improving the processability of the polymer blend. The rheology modifier facilitates the formation of finer, more uniform filament characteristics in the melt-blown fibers.[000118] In some exemplary embodiments, the melt-blown composite nonwoven webs contain from 100 to 600 gsm or from 200 to 500 gsm, or from 300 to 400 gsm of SAP. In some exemplary embodiments, the melt-blown composite nonwoven webs contain from 5 to 40 gsm, or from 10 to 30 gsm, or from 15 to 25 gsm of nonwoven. One exemplary melt-blownATTY DOCKET: DSGI-1015WOcomposite contains 10 gsm of nonwoven and 300 gsm or SAP. Another exemplary melt-blown composite contains 20 gsm of nonwoven and 360 gsm of SAP.[000119] In some embodiments, the melt-blown fibers disclosed herein include from 2 to 20 wt.%, 5 to 15 wt.%, or about 5 wt.% of a wetting agent, based on a total weight of the melt-blown fibers. The wetting agent functions to promote hydrophilicity, improve wetting, and provide at least some improvement to wicking in the melt-blown composite. In some experiments, above an optimum concentration of wetting agent (about 5 wt.%), no additional improvements in wetting properties are observed. Too much wetting agent can cause poor filament formation, resulting in coarser filaments. The wetting agent is compatible with other chemistries within the PP filaments. Wetting agent can migrate away from the surface of the filaments, depending on the crystalline structure of the filaments. Thus, wetting agents that are stable over time should be used in the melt-blown composites.Elastomer[000120] In some embodiments, the melt-blown fibers disclosed herein include from 20 to 90 wt.%, or from 30 to 80 wt.%, or from 40 to 70 wt.%, or from 50 to 60 wt.% of elastomer, preferably about 60 wt.% based on a total weight of the melt-blown fibers. The elastomer improves the elasticity of the melt-blown composite nonwoven web and allows the filaments to expand when the SAP expands. Some effects of incorporating elastomer into the melt-blown polymer were demonstrated in an experiment testing nonwoven sachets formed from PP melt-blown with increasing elastomer contents. The images of FIGS. 10A-10G show a nonwoven sachet formed from a PP melt-blown with increasing elastomer contents and the images of FIGS. 11A-11F are close-up views of the melt-blown composites of FIGS. 10B-10G. In the experiment, the sachets were filled with a small amount of SAP and then immersed in water with red coloring added. The SAP was then allowed to absorb and expand while contained in the sachet. FIG. 10A is a photograph of a polypropylene sachet prior to testing. FIG. 10B is a photograph of a polypropylene sachet containing no elastomer after 2 minutes of exposure to water. It is clear that the sachet of FIG. 10B does not show significant swelling. FIG. 11A is a close up of the fibers of the sachet of FIG. 10B, showing the fineness of the fibers thereof. FIG. 10C is a photograph of a polypropylene sachet composed of melt-blown polypropylene fibers that contain 20 wt.% elastomer after 2 minutes of exposure to water. It is clear that the sachet of FIG. 10C allows more swelling than that of FIG. 10B. FIG. 1 IB is a close up of the fibers of the sachet of FIG. 10C, showing that the fibers are coarser than those if FIG. 10B. FIG. 10D is a photograph of a polypropylene sachet containing 50 wt.% elastomer after 2 minutes of exposure to water. It is clear that the sachet of FIG. 10D allows more swelling thanATTY DOCKET: DSGI-1015WOthat of FIG. IOC. FIG. 11C is a close up of the fibers of the sachet of FIG. 10D, showing that the fibers are coarser than those if FIG. 10E. FIG. 10E is a photograph of a polypropylene sachet containing 70 wt.% elastomer after 2 minutes of exposure to water. It is clear that the sachet of FIG. 10E allows more swelling than that of FIG. 10D. FIG. 1 ID is a close up of the fibers of the sachet of FIG. 10E, showing that the fibers are coarser than those if FIG. 10D. FIG. 10F is a photograph of a polypropylene sachet containing 90 wt.% elastomer after 2 minutes of exposure to water. It is clear that the sachet of FIG. 10F allows more swelling than that of FIG. 10E. FIG. 1 IE is a close up of the fibers of the sachet of FIG. 10F, showing that the fibers are coarser than those if FIG. 10E. FIG. 10G is a photograph of a polyer sachet containing 100 wt.% elastomer after 2 minutes of exposure to water. It is clear that the sachet of FIG. 10G allows more swelling than that of FIG. 10F. FIG. 1 IF is a close up of the fibers of the sachet of FIG. 10G, showing that the fibers are coarser than those if FIG. 10F. In some embodiments the individual fibers or filaments are from 0.4 to 10 microns, or 0.5 to 7 microns, or 1 to 5 microns, or 2 to 4 microns in diameter.[000121] In the experiment reflected in FIGS. 10A-1 IF, it was found that increasing the elastomer content allows the sachets to expand more to accommodate the SAP swelling. Conversely, increasing the PP content of the sachets reduces the swelling capability of the SAP. It was also found that coarser melt-blown filaments were produced when higher levels of elastomer were used, whereas, finer melt-blown filaments are preferable, in some embodiments, due to improved quality and appearance. Thus, the amount of elastomer versus polymer (e.g., polypropylene) can be adjusted to balance the need for swelling versus the need for fine fibers.[000122] In an unexpected and surprising result, use of an elastomer was found to promote tackiness in the melt-blown composites. That is, the tackiness of the hot melt-blown filaments increased as the concentration of elastomer was increased. Tackiness of the melt-blown fibers facilitates the SAP particles to stick to the fibers upon impact. The bar graph of FIG. 12 shows an effect of the amount of elastomer on the ability of SAP to stick to the melt-blown fibers of the melt-blown composite web. In the experiment reflected by the data of FIG.12, webs of nonwoven without SAP were produced having different elastomer contents. The nonwoven fabric webs were then heated to 140°C and a specific amount of SAP was sprinkled on each web. After cooling the webs, the samples were shaken and loose SAP was removed and weighed. The amount of SAP lost was recorded was then recorded. As shown in FIG. 12, two different commercially available polymer systems, Vistamaxx 7050BF and Kraton MD1648, were tested with varying elastomer concentrations added thereto. The elastomer concentrations added to both of the base polymer systems were 0 wt.%, 20 wt.%, 50 wt.%, andATTY DOCKET: DSGI-1015WO70 wt.%, with the Kraton MD1648 also being tested at 90 wt.% and 100 wt.% elastomer concentrations. For both polymer systems, it can be seen from the data of FIG. 12 that the average SAP loss decreases with increasing elastomer content.[000123] The melt-blown composites disclosed herein have several advantages, including: (1) the use of elastomers in in the melt-blown formulations of PP based filaments, particularly when combined with SAP with the elastomer enabling the PP filaments to expand and move as the SAP swells; and (2) the enhanced tackiness of the fdaments (when hot), caused by the addition of the elastomer, enabling the SAP to be captured and held more efficiently by the web scaffold.Thermoplastic Polyurethane[000124] In some embodiments the melt-blown composites include a combination of superabsorbents (SAP powder) and a melt-blow polymer that is inherently elastic and capable of being extruded in a melt-blowing process. The polymer may be a block copolymer having a hard segment and a soft segment. The polymer can be a thermoplastic elastomer. For example, in one exemplary embodiment, the polymer is a thermoplastic polyurethane (TPU). The filaments of TPU form a net or scaffold about the SAP powder particles to capture and hold the SAP in place. The filaments of TPU can be hydrophilic and promote liquid flow from the surface of the melt-blown composite to the interior and the SAP particles. The filaments of TPU are configured and arranged to avoid blocking the ability of the SAP to absorb and expand. The filaments of TPU have sufficient structural integrity to retain the SAP in both wet and dry states.[000125] TPU filaments are inherently elastomeric, hydrophilic and somewhat absorbent. Thus, TPU provides a single component route to making the scaffold component of the melt-blown composite nonwoven web. The use of TPU filaments in the melt-blown composites provide for several advantages over the use of polypropylene or polyethylene filaments. PP and PE are not are hydrophobic, such that additives are required to make the PP and PE filaments more elastomeric or hydrophilic. Whereas, TPU is inherently hydrophilic and elastomeric (e.g., by virtue of the chemistry of the polyol block of the polyol-diisocyanate-chain extender combination that forms the TPU polymer). Unlike melt-blown materials based on PP / PE chemistry, additional compounds to promote wettability and elasticity are not required for TPU filaments. Without being bound by theory, TPU is also believed to be, potentially, more biodegradable than PP / PE. Further, the component building blocks of the TPU chemistry are more easily sourced from sustainable sources than those of PP and PE.ATTY DOCKET: DSGI-1015WO[000126] The raw materials suitable for use in the TPU based melt-blown composites disclosed herein include superabsorbent polymer particles (e.g., Sandia IM930, BASF, Nippon Shokubai); TPU (e.g., Estane 58245 from Lubrizol, Elastollan 1190 A10 from BASF or Hytrel 4068 from Celanase); and, optionally, substrate nonwoven (e.g., 15gsm spunbond PP for topsheet nonwoven, or lOgsm hydrophilic SMS for core wrap nonwoven, or 40-80gsm airthrough PET nonwoven for ADL). In one exemplary formulation, the scaffold of the melt-blown composite nonwoven web contains 100 wt.% of TPU (excluding the SAP content), and lacks any wetting agent or elastomer. In other embodiments, the nonwoven web contains mixtures TPU with PP and / or PE. The inclusion of PP with the TPU may increase the structural integrity of the nonwoven web. For example, the nonwoven web may contain from 10 to 50 wt.% PP, or from 20 to 40 wt.% PP, based on the total weight of the combination of the PP and the TPU. The melt-blown composite web may contain from 100 to 600gsm, or from 200 to 500gsm, or from 300 to 400gsm of SAP. The melt-blown composite web may contain from 5 to 40 gsm, or from 10 to 30 gsm, or from 15 to 25 gsm of nonwoven (e.g. TPU). In one exemplary formulation, the melt-blown composite contains 30gsm nonwoven and 300gsm SAP. Embodiments that use TPU nonwovens as a scaffold for an absorbent composite with SAP exhibit advantages including: (1) the inherent elasticity of the TPU scaffold provides the means for the SAP to readily expand; (2) some TPU chemistries (e.g., Estane 58245) provide for expansion of the filament when wet; and (3) the resultant absorbent composite changes dimensions significantly when wet, as the SAP and the TPU filaments expand.[000127] FIG. 13 are images that show the behavior of Estane 58245 TPU when wet (on the left) and air dried (on the right). The Estane 58245 TPU melt-blown fibers show a near instantaneous 17% increase in test specimen size when in contact with water, and returned to its original size as the liquid was air evaporated. Whereas, Hytrel 4068 and Elastollan 1190 A10 exhibited no such size changes when wet versus dry.[000128] FIGS. 14 and 15 are images showing that an expansion affect, on a flat surface. With reference to FIGS. 14 and 15, the composites 1400 each include relatively dry regions 1402 and relatively wet regions 1404. The wet regions 1404 have absorbed liquid (shown in red) and, as a result of this absorption, the composite 1400 has expanded about the wet regions, forming barriers 1406.[000129] The TPU filaments have improved tackiness which promotes much better adhesion and capture of the SAP particles resulting in excellent integrity (minimal SAP loss) in the wet and dry states. The expansion of the melt-blown composite can be used to create interesting and beneficial effects within an absorbent core. For example, the expansion of theATTY DOCKET: DSGI-1015WOmelt-blown composite can be exploited to: (1) open up or close off areas of the absorbent core in layers of the core; (2) lift up barriers to fluid flow at the sides of the core; and (3) create folds and concertina effects that slow down the flow of fluid or increase the surface area of the absorbent surface. As the composite expands, a 3D shape is formed in the melt-blown composites as the additional material is pushed upward. This expansion can form barriers to contain the flow of fluid in and throughout the absorbent core.[000130] TPU is a multi-phase block copolymer that is created when three basic raw materials are combined together in a specific way. The individual components required to produce a TPU are: (1) a polyol or long-chain diol; a chain extender or short-chain diol; and a diisocyanate. The soft block, built out of a polyol and an isocyanate, is responsible for the flexibility and elastomeric character of a TPU. The hard block, constructed from a chain extender and isocyanate, gives a TPU its toughness and physical performance properties. TPU has a cross-linking structure of a thermoplastic elastomer versus a thermoset rubber. There are no chemical cross-links in TPU’s unlike thermoset rubbers or casted polyurethane systems. The morphology of a TPU includes physical cross-links that melt out under heat and repack when the material is cooled.Exemplary Composites and Compositions[000131] Table 1, below, shows the particle size distribution of an exemplary population of SAP.Table 1 - SAP Particle Size Distribution> <> <> <> <> <<[000132] In the exemplary population of SAP in table 1, the majority (about 65% of the particles based on a total number of the particles in the entire population) of SAP particles have an average particle size or diameter of between 300 and 600 microns, about 25% of the SAP particles have an average particle size or diameter of less than 300 microns, and about 10% of the SAP particles have an average particle size or diameter of greater than 600 microns. AsATTY DOCKET: DSGI-1015WOdiscussed in reference to FIGS. 8A-8G, the larger sized SAP particles will tend to be captured toward one side of the melt-blown fibers (e.g., in the side of the melt-blown fibers forming a scaffolding structure), while the smaller sized SAP particles will tend to be captured toward the other side of the melt-blown fibers (e.g., in the side of the melt-blown fibers forming a retaining structure. Thus, the population of SAP, and its particle size distribution, can be selected to provide the desired gradient SAP distribution in the composites.[000133] Tables 2 and 3, below, show details of five exemplary compositions.Table 2 - CompositionsTable 3 - Properties and CharacteristicsATTY DOCKET: DSGI-1015WO> <[000134] FIG. 16 includes images of the Sample Nos. 1-5 of Tables 2 and 3 prior to exposure to liquid. FIG. 17A includes images of Sample 1, a TPU melt-blown composite, before expansion (on the left) and after exposure to liquid and expansion (on the right). The region of the TPU melt-blown composite in FIG. 17A where liquid is absorbed is shown in blue. The SAP distribution in Sample 1 was uniform, stable, and exhibited dry and wet integrity. The blue area in FIG. 17A shows where absorption and swelling primarily occurred in Sample 1. FIG> 17B is a detail view of a portion of the composite of FIG. 17A.[000135] Table 4, below, shows some laboratory results for some exemplary samples.Table 4 - Laboratory Results1flowrate at 7mL / sATTY DOCKET: DSGI-1015WO[000136] Table 4 shows results for Samples 1-5, as well as sample 93 / 92 PP x SAP and sample 860 / 1 PP x SAP. FIGS. 18 and 19 show additional images of samples 1-5 and the two additional samples of Table 4 in swollen states. From the images, TPU samples show the most expansion. The regions of the composite in FIGS. 18 and 19 where liquid is absorbed are shown in blue.[000137] FIGS. 20-23 are swell curves for some of the samples. FIGS. 20-23 show the rate of swelling of the SAP in millimeters per gram of SAP. FIGS. 21 and 22 show the rate of change of the swelling every five seconds after water is added to the material. In these curves, the “Control SAP” is the free, unbound SAP (the same SAP is used in all the samples), E3 and E4 are two TPU materials, and V2.x are different PP based materials. Preferably, the SAP will swell as quickly as possible and as have the performance as close as possible to SAP that is free and unbound by any form of adhesion or entanglement (the red control line). Binding the SAP in the material affects the free swell rate curve and, in some embodiments, a goal is to minimize this restriction in swelling rate. The TPU chemistries exhibit more absorption (more swelling) in the initial part of the curve. With the PP chemistries, there is a delay in the fast rate of swelling.Additional Concepts[000138] U.S. Patent No. 11,027,039 (‘039 Patent) discloses fuzzy-SAP particles, and is incorporated herein by reference in its entirety. The fuzzy-SAP particles of the ‘039 Patent provide for greater permeability and wicking potential for an absorbent core, reduces the density of the SAP, and promotes better performance of the core. In some embodiments, the melt-blown composite nonwoven webs disclosed herein, including melt-blown fibers, can include or be mixed with the fuzzy-SAP particles to secure the fuzzy-SAP particles through the adhesion of the fuzzy-SAP to the MB scaffold.[000139] In some embodiments, the wettablilty of the melt-blown composites can be maximized or at least increased. The wettability of the melt-blown fibers and the resultant core affects how well the core can hold, distribute, and absorb fluid. Various ways of the wettability can be maximized by: (1) use and optimization of a wetting agent; and / or (2) plasma / corona treatment. The optimization of the wetting agent can include identifying a wetting agent that will work best (e.g., is compatible) with the chosen melt-blown polymer; optimizing the level of wetting agent added; using different types of wetting agents and / or different concentrations of wetting agents in different parts of the core; and ensuring the wetting agent remains functional on the surface of the filament. Treatment of the melt-blown composite web with plasma or corona can promote greater wettability of the fibers and surfaces within the core.ATTY DOCKET: DSGI-1015WO[000140] In some embodiments, the density of the core is minimized. In order to achieve a SAP target basis weight of 300-380g / m2, for example, the core may have a relatively high-density SAP distribution. To lower the density, in some embodiments a lower density, lower basis weight material is used and subjected to physical / mechanical processes to bulk up the material and increase the SAP basis weight. Some such exemplary processes include: folding the material, crimping the material, crepeing the material, layering the material, providing for contraction by elastication of the material, pleating the material, shingling the material, and / or profding and providing SAP free lanes in the melt-blown composite by placing SAP in greater concentrations where it is needed and lesser concentrations where it is not and introducing SAP free lanes and channels to enhance fluid flow directionally. U.S. Patent No. 11,090,203 and U.S. Patent Publication No. 2019 / 0290505, which are both incorporated herein by reference in their entireties, provide some additional relevant disclosure related to methods for processing the cores in accordance with this paragraph.[000141] In some embodiments, pulsed air jets are used in the melt blowing process. The pulsed air jets produce a narrower fiber size distribution, crimped / curled fibers, and bulkier nonwoven webs. The perturbation frequency of the pulsed air jets determines the effects on the fiber such that the resultant melt-blown composite web structure can be affected by varying the pulse frequency. U.S. Patent No. 5,811,178, the entirety of which is incorporated herein by reference, discloses an example of a multi-bank process and resulting profiled web structure.[000142] In some embodiments, rather than, or in addition to, using PP or TPU polymers to form the fibers, other polymers, such as PE. Are used. In some embodiments, at least two polymers are used to form a bicomponent fiber for production of curled / crimped, bondable fibers.[000143] In some embodiments, rather than, or in addition to, using SAP, other absorbents are used to replace or supplement the SAP. For example, cellulose gum and / or superabsorbents from biodegradeable or sustainable sources can be used.Applications[000144] The melt-blown composites in accordance with embodiments of the present disclosure provide for numerous benefits including, but not limited to: (1) a reduced raw material requirement - as little as two components can be used to form the melt-blown composite including SAP and the melt-blown polymer filaments; (2) a lack of fluff pulp - some fluffless technologies are based on using bulky nonwovens that require SAP to be put inside and held by a pre-made nonwoven material, whereas, embodiments of the present process forms and manufactures nonwoven around the SAP; (3) a lack of adhesive - some flufflessATTY DOCKET: DSGI-1015WOtechnologies rely on adhesive to hold the SAP in place - adhesive can impair the performance of the SAP by blocking the absorption of water into the SAP particle and resisting the expansion forces within the SAP particle as the particle tries to expand and swell; (4) and the chemistry of the melt-blown nonwoven filaments can be customized to make the melt-blown composite wettable and elastic - there are a wide variety of chemistries that can be used to make the fdament properties customizable.[000145] The nonwoven composites disclosed herein can be used incorporated into various absorbent articles. The absorbent articles may be or include, but are not limited to, baby diapers, baby pants, refastenable pants for babies, adult incontinence diapers, adult incontinence pants, absorbent pads for two-piece baby diapers or adult diapers, feminine hygiene products, changing mats, pet diapers, and pet pads. The nonwoven composites may also be used in other applications where liquid (e.g., water) absorbing materials are required (e.g., in a sheet form) including industrial cleaning solutions, chemical spill absorbent pads, flood barriers and flood protection mats.[000146] In some embodiments, the absorbent articles include a single layer of the nonwoven composite material. In other embodiments, the absorbent articles include multiple layers of the nonwoven composite material (e.g., stacked layers) to provide additional levels of performance. In embodiments containing multiple layers of the nonwoven composite material, the each layer can be identical or can have different functionalities derived from changes in the type or amount of superabsorbent, the type or amount of melt-blown polymer, or by changing the way that the components are distributed and arranged, such as by creating regions that are substantially free of superabsorbent. Relatively simple structures including the nonwoven composites may suitable for relatively lower cost applications, such as changing pads where low levels of absorbency are required over a wider area of material. Relatively complex multilayered structures including the nonwoven composites may be suitable for more complex products, such as baby diapers where relatively high levels of absorbency and rapid absorbing properties are required within a small, contained structure.Exemplary Embodiments[000147] One skilled in the art would appreciate that various concepts disclosed herein can be combined in numerous different ways and configurations. Without limiting the potential combinations, the following exemplary embodiments provide some examples of some of the combinations that may be made.[000148] As one exemplary method embodiment, a method of forming an absorbent composite is provided. The method includes melt-blowing a first polymer to form a first melt-ATTY DOCKET: DSGI-1015WOblown web including a plurality of filaments of the first polymer and directing the first melt-blown web toward a surface. The method includes directing a first stream of superabsorbent polymer particles to impact the first melt-blown web such that at least a portion of the superabsorbent polymer particles are distributed within the first melt-blown web to form a first melt-blown composite. The first stream of superabsorbent polymer particles impact the first melt-blown web at a location that is upstream of the surface. The method includes depositing the first melt-blown composite onto the surface.[000149] In the method of the above embodiment, the first melt-blown web can be directed toward the surface in a first direction, wherein the first stream of superabsorbent polymer particles are directed toward the first melt-blown web in a second direction, and wherein the second direction is at an angle relative to the first direction.[000150] In the method of any of the above embodiments, the angle can be controlled to reduce loss of the superabsorbent polymer particles upon impact of the superabsorbent polymer particles with the first melt-blown web, to reduce an amount of loose superabsorbent polymer particles in the composite material, or combinations thereof.[000151] In the method of any of the above embodiments, the angle can be from 80 degrees to 100 degrees.[000152] In the method of any of the above embodiments, the surface can be a surface of a conveyer belt or a surface of a substrate nonwoven.[000153] The method of any of the above embodiments can include applying a cover nonwoven over the first melt-blown composite such that the first melt-blown composite is positioned between the cover nonwoven and the substrate nonwoven.[000154] The method of any of the above embodiments can include the cover nonwoven adhered to the first melt-blown composite via adhesive, ultra sonic bonding, or thermal bonding.[000155] The method of any of the above embodiments can include directing a second stream of superabsorbent polymer particles to impact the first melt-blown web such that at least a portion of the superabsorbent polymer particles are distributed within the first melt-blown web to form the first melt-blown composite, wherein the second stream of superabsorbent polymer particles impact the first melt-blown web at a location that is upstream of the surface.[000156] The method of any of the above embodiments can include the second stream of superabsorbent polymer particles impacting the first melt-blown web at a location that is downstream of the first stream of superabsorbent polymer particles.[000157] The method of any of the above embodiments can include the first stream of superabsorbent polymer particles impacting a first side of the first melt-blown web, whereinATTY DOCKET: DSGI-1015WOthe second stream of superabsorbent polymer particles impact a second side of the first melt-blown web, and wherein the first side is opposite the second side.[000158] The method of any of the above embodiments can include directing a first stream of additive particles to impact the first melt-blown web such that at least a portion of the additive particles are distributed within the first melt-blown web to form the first melt-blown composite, wherein the first stream of additive particles impact the first melt-blown web at a location that is upstream of the surface.[000159] The method of any of the above embodiments can include melt-blowing a second polymer to form a second melt-blown web including a plurality of filaments of the second polymer; directing the second melt-blown web toward the surface; and combining the second melt-blown web with the first melt-blown composite, forming a second melt-blown composite.[000160] The method of any of the above embodiments can include depositing the second melt-blown web onto the surface, and depositing the first melt-blown composite onto the second melt-blown web.[000161] The method of any of the above embodiments can include depositing the second melt-blown web onto the first melt-blown composite on the surface.[000162] The method of any of the above embodiments can include directing a second stream of superabsorbent polymer particles to impact the second melt-blown web such that at least a portion of the superabsorbent polymer particles are distributed within the second melt-blown web, wherein the second stream of superabsorbent polymer particles impact the second melt-blown web at a location that is upstream of the surface.[000163] The method of any of the above embodiments can include the superabsorbent polymer particles of the first stream being the same as or different than the superabsorbent polymer particles of the second stream.[000164] The method of any of the above embodiments can include directing a first stream of additive particles to impact the second melt-blown web such that at least a portion of the additive particles are distributed within the second melt-blown web, wherein the first stream of additive particles impact the second melt-blown web at a location that is upstream of the surface.[000165] The method of any of the above embodiments can include the first polymer and the second polymer being the same or different.[000166] The method of any of the above embodiments can include melt-blowing a third polymer to form a third melt-blown web including a plurality of filaments of the third polymer;ATTY DOCKET: DSGI-1015WOdirecting the third melt-blown web toward the surface; and combining the third melt-blown web with the second melt-blown composite, forming a third melt-blown composite.[000167] The method of any of the above embodiments can include the first melt-blown composite being positioned between the second and third melt-blown webs.[000168] The method of any of the above embodiments can include directing a stream of superabsorbent polymer particles to impact the third melt-blown web such that at least a portion of the superabsorbent polymer particles are distributed within the third melt-blown web, wherein the stream of superabsorbent polymer particles impact the third melt-blown web at a location that is upstream of the surface.[000169] The method of any of the above embodiments can include directing a stream of additive particles to impact the third melt-blown web such that at least a portion of the additive particles are distributed within the third melt-blown web, wherein the stream of additive particles impact the third melt-blown web at a location that is upstream of the surface.[000170] The method of any of the above embodiments can include the first melt-blown web having a first surface and a second surface, wherein the first stream of superabsorbent polymer particles is directed to impact with the first surface, wherein impact of the first stream of superabsorbent polymer particles with the first surface opens a network of filaments of the first melt-blown web at the first surface, forming a gradient bulk density and gradient void volume in the first melt-blown web such that a void volume of the first melt-blown web is greater at the first surface than the second surface, and such that a bulk density of the first melt-blown web is less at the first surface than the second surface.[000171] The method of any of the above embodiments can include impacting the first stream of superabsorbent polymer particles with the first melt-blown web results in a gradient distribution of the superabsorbent polymer particles within the first melt-blown web such that a population of the superabsorbent polymer particles positioned closer to the second surface have a smaller average particle size than a population of the superabsorbent polymer particles positioned closer to the first surface.[000172] The method of any of the above embodiments can include the first melt-blown web forming a scaffolding structure at the first surface including filaments of the first melt-blown web that entangle the superabsorbent polymer particles.[000173] The method of any of the above embodiments can include the first melt-blown web forming a retention structure at the second surface including filaments of the first melt-blown web that prevent passage of the superabsorbent polymer particles through the second surface.ATTY DOCKET: DSGI-1015WO[000174] The method of any of the above embodiments can include the first melt-blown web being a curtain of filaments of the first polymer.[000175] The method of any of the above embodiments can include the filaments being entangled together.[000176] The method of any of the above embodiments can include, at impact of the superabsorbent polymer particles with the first melt-blown web, the filaments of the first melt-blown web being at least partially molten and tacky.[000177] The method of any of the above embodiments can include directing the first melt-blown web is a continuous web that is directed to the surface, and wherein the first stream is a continuous stream that is directed to impact with the first melt-blown web.[000178] The method of any of the above embodiments can include cooling the first melt-blown composite.[000179] The method of any of the above embodiments can include incorporating the first melt-blown composite into a diaper or sanitary napkin.[000180] The method of any of the above embodiments can include melt-blowing the first polymer to form the first melt-blown web includes extruding the plurality of filaments of the first polymer in a first hot air stream, wherein the first melt-blown web is directed toward the surface in the first hot air stream;[000181] The method of any of the above embodiments can include the first stream of superabsorbent polymer particles being directed to impact the first melt-blown web in a second hot air stream; and the second hot air stream intersects the first hot air stream upstream of the surface.[000182] The method of any of the above embodiments can include directing the first stream of superabsorbent polymer particles including directing the superabsorbent polymer particles from a venturi device.[000183] The method of any of the above embodiments can include the superabsorbent polymer particles being mixed with a hot air stream in the venturi device.[000184] The method of any of the above embodiments can include hot air extruding the first polymer from an extruder.[000185] The method of any of the above embodiments can include the superabsorbent polymer particles adhering to the filaments of the first melt-blown web without use of an adhesive.[000186] The method of any of the above embodiments can include the first melt-blown web being directed toward the surface via gravity.ATTY DOCKET: DSGI-1015WO[000187] The method of any of the above embodiments can include the surface being a surface of a conveyor belt, and wherein a speed of the conveyer belt is coordinated with a throughput of the first melt-blown web to affect a basis weight of the first melt-blown composite.[000188] The method of any of the above embodiments can include directing a stream of additive particles to impact the first melt-blown web, the second melt-blown web, or both, such that at least a portion of the additive particles are distributed within one or both of the first and second melt-blown webs, wherein the stream of additive particles impacts the first and / or second melt-blown webs at a location that is upstream of the surface.[000189] The method of any of the above embodiments can include the use of additive particles including polylactic acid (PLA) short fibers, polyethylene terephthalate (PET) hollow fibers, calcium carbonate fibers, omya fibers, perlite, pumice, zeolite, staple fibers, chitosan, collagen, PLA, polypropylene (PP), polyurethane (PU), polypropylene / polyethylene (PP / PE) bicomponent fibers, granules, wood pulp, cellulose acetate fibers, viscose fibers, cotton fibers, bamboo fibers, hemp fibers, micro-fibrillated cellulose (MFC), or thermally expandable microspheres.[000190] The method of any of the above embodiments can include the use of additive particles that include hydrophilic fibrillated nanofibers.[000191] The method of any of the above embodiments can include the use of additive particles including acidic or basic water absorbent resin particles.[000192] The method of any of the above embodiments can include the use of additive particles including wetting agents or flow promoters.[000193] The method of any of the above embodiments can include the first polymer being melt-blown from an extruder to form the first melt-blown web, and wherein a distance between the extruder of the surface is from 40 to 80 cm.[000194] The method of any of the above embodiments can include the first stream being directed from a nozzle, and wherein a distance between the nozzle and the first melt-blown web is from 4 to 8 cm.[000195] The method of any of the above embodiments can include a throughput of the first melt-blown web of from 0.5 to 2 kg of the first melt-blown web per minute, and wherein a throughput of the first stream is from 9.6 to 38.6 kg of superabsorbent polymer particles per minute.[000196] The method of any of the above embodiments can include the superabsorbent polymer particles being at ambient temperature when impacted with the first melt-blown web,ATTY DOCKET: DSGI-1015WOand wherein the first melt-blown web is at a temperature ranging from 150°C to 250°C when impacted with the superabsorbent polymer particles.[000197] The method of any of the above embodiments can include the superabsorbent polymer particles turbulently mixing with the first melt-blown web.[000198] The method of any of the above embodiments can include the superabsorbent polymer particles adhering or bonding with the first melt-blown web via tack and / or van der Waals interactions.[000199] The method of any of the above embodiments can be an online process in which the first melt-blown composite is directed to an in-line a diaper manufacturing process.[000200] The method of any of the above embodiments can be an offline process in which the first melt-blown composite is collected subsequent use.[000201] The method of any of the above embodiments can include the first melt-blown web having a basis weight of from 10 to 50 g / m2.[000202] The method of any of the above embodiments can include the first melt-blown web having a thickness of from 0.05 mm to 0.50 mm.[000203] The method of any of the above embodiments can include the first melt-blown composite having a SAP loading o from 100 to 700 g / m2.[000204] The method of any of the above embodiments can include a layer of SAP in the first melt-blown composite having a thickness of from 0.1 mm to 1 mm.[000205] The method of any of the above embodiments can include a basis weight of the first melt-blown composite ranging from 200 to 800 g / m2.[000206] The method of any of the above embodiments can include a thickness of the first melt-blown composite ranging from 0.30 mm to 2.50 mm.[000207] The method of any of the above embodiments can include a density of the first melt-blown composite ranging from 300 to 800 kg / m3.[000208] The method of any of the above embodiments can include the first polymer including a polyolefin.[000209] The method of any of the above embodiments can include the first polymer including polypropylene, an elastomer, polyethylene, a rheology modifier, a wetting agent, or any combination thereof.[000210] The method of any of the above embodiments can include the first polymer including a block copolymer having a hard segment and a soft segment.[000211] The method of any of the above embodiments can include the first polymer including a thermoplastic elastomer.ATTY DOCKET: DSGI-1015WO[000212] The method of any of the above embodiments can include the first polymer including a thermoplastic polyurethane.[000213] The method of any of the above embodiments can include the first polymer including filaments that are hydrophilic, elastic, and absorbent.[000214] The method of any of the above embodiments can include the first polymer including a thermoplastic polyurethane and a polyolefin.[000215] The method of any of the above embodiments can include the using a population of superabsorbent polymer particles that have particle sizes ranging from about 45 microns to about 850 microns.[000216] The method of any of the above embodiments can include melting and extruding the first polymer from a die head of an extruder with a hot air stream.[000217] The method of any of the above embodiments can include the first melt-blown composite being pulpless and fluffless.[000218] The method of any of the above embodiments can include the first melt-blown composite lacking an adhesive.[000219] As one exemplary nonwoven composite embodiment, a nonwoven composite can include a first nonwoven web having a three-dimensional network of filaments, wherein the first nonwoven web has a first surface and a second surface, wherein the three-dimensional network of filaments has a gradient void volume such that a void volume at the first surface is greater than a void volume at the second surface, and wherein the three-dimensional network of filaments form a first scaffold structure at the first surface; and a first plurality of superabsorbent polymer particles dispersed within first nonwoven web, wherein the superabsorbent polymer particles are at least partially positioned within interstitial void volume of the first scaffold structure, and wherein the filaments of the first scaffold structure interlace, at least partially, about the superabsorbent polymer particles.[000220] In the nonwoven composite above, the three-dimensional network of filaments can form a first retention structure at the second surface.[000221] In any of the nonwoven composites above, the superabsorbent polymer particles can have a gradient size distribution with the nonwoven web such that first superabsorbent polymer particles are positioned closer to the first surface and second superabsorbent polymer particles are positioned closer to the second surface, and wherein the first superabsorbent polymer particles are larger than the second superabsorbent polymer particles.[000222] Any of the nonwoven composites above can include a second nonwoven web including a three-dimensional network of filaments and having a first surface and a secondATTY DOCKET: DSGI-1015WOsurface, wherein the first surface of the second nonwoven web is coupled with the first surface of the first nonwoven web such that superabsorbent polymer particles are positioned between the second surface of the first nonwoven web and the second surface of the second nonwoven web.[000223] Any of the nonwoven composites above can include a third nonwoven web comprising a three-dimensional network of filaments, wherein the third nonwoven web has a first surface and a second surface, wherein the three-dimensional network of filaments has a gradient void volume such that a void volume at the first surface is greater than a void volume at the second surface, and wherein the three-dimensional network of filaments form a second scaffold structure at the first surface; and a second plurality of superabsorbent polymer particles dispersed within third nonwoven web, wherein the superabsorbent polymer particles are at least partially positioned within interstitial void volume of the second scaffold structure, and wherein the filaments of the second scaffold structure interlace, at least partially, about the superabsorbent polymer particles; wherein the first surface of the third nonwoven web is coupled with the second surface of the second nonwoven web such that the superabsorbent polymer particles of the nonwoven composite are positioned between the second surface of the first nonwoven web and the second surface of the third nonwoven web.[000224] Any of the nonwoven composites above can include a substrate nonwoven coupled with the first nonwoven web.[000225] Any of the nonwoven composites above can include a cover nonwoven coupled with the first nonwoven web such that the first nonwoven web is positioned between the cover nonwoven and the substrate nonwoven.[000226] Any of the nonwoven composites above can include the first plurality of superabsorbent polymer particles being the same as or different than the second plurality of superabsorbent polymer particles.[000227] Any of the nonwoven composites above can include one or more additives dispersed within the he first nonwoven web such that at least a portion of the additives are distributed within the first nonwoven web.[000228] Any of the nonwoven composites above can include filaments that entangle the superabsorbent polymer particles within the scaffold structure.[000229] Any of the nonwoven composites above can include the following additives: polylactic acid (PLA) short fibers, polyethylene terephthalate (PET) hollow fibers, calcium carbonate fibers, omya fibers, perlite, pumice, zeolite, staple fibers, chitosan, collagen, PLA, polypropylene (PP), polyurethane (PU), polypropylene / polyethylene (PP / PE) bicomponentATTY DOCKET: DSGI-1015WOfibers, granules, wood pulp, cellulose acetate fibers, viscose fibers, cotton fibers, bamboo fibers, hemp fibers, micro-fibrillated cellulose (MFC), thermally expandable microspheres, hydrophilic fibrillated nanofibers, acidic or basic water absorbent resin particles, wetting agents or flow promoters.[000230] Any of the nonwoven composites above can include superabsorbent polymer particles that adhere or bond with the filaments via tack.[000231] Any of the nonwoven composites above can include superabsorbent polymer particles that adhere or bond with the filaments via van der Waals interactions.[000232] Any of the nonwoven composites above can include the first nonwoven web having a basis weight of from 10 to 50 g / m2.[000233] Any of the nonwoven composites above can include the first nonwoven web having a thickness of from 0.05 mm to 0.50 mm.[000234] Any of the nonwoven composites above can include the first nonwoven web having a SAP loading o from 100 to 700 g / m2.[000235] Any of the nonwoven composites above can include a layer of SAP in the first nonwoven web has a thickness of from 0.1 mm to 1 mm.[000236] Any of the nonwoven composites above can include a basis weight of the nonwoven composite that ranges from 200 to 800 g / m2.[000237] Any of the nonwoven composites above can include a thickness of the nonwoven composite that ranges from 0.30 mm to 2.50 mm.[000238] Any of the nonwoven composites above can include a density of the nonwoven composite that ranges from 300 to 800 kg / m3.[000239] Any of the nonwoven composites above can include filaments of the first nonwoven web that include a polyolefin filaments such as polypropylene or polyethylene.[000240] Any of the nonwoven composites above can include an elastomer.[000241] Any of the nonwoven composites above can include a rheology modifier and / or a wetting agent.[000242] Any of the nonwoven composites above can include a block copolymer having a hard segment and a soft segment.[000243] Any of the nonwoven composites above can include a thermoplastic elastomer.[000244] Any of the nonwoven composites above can include a thermoplastic polyurethane.[000245] Any of the nonwoven composites above can include filaments that are hydrophilic, elastic, and absorbent.ATTY DOCKET: DSGI-1015WO[000246] Any of the nonwoven composites above can include a population of superabsorbent polymer particles having particle sizes ranging from about 45 microns to about 850 microns.[000247] Any of the nonwoven composites above can be pulpless and fluffless.[000248] Any of the nonwoven composites above can lack an adhesive.[000249] As one exemplary system embodiment, a system for making a nonwoven composite can include a melt-blowing extruder positioned to provide melt-blown polymer fdaments; a conveyer positioned to receive the melt-blown polymer filaments from the meltblowing extruder; and a SAP dispenser positioned to direct SAP onto the melt-blown polymer filaments exiting the melt-blown extruder and upstream of the conveyer to form a nonwoven composite.[000250] The embodiment the system above can include the melt-blowing extruder positioned and arranged to direct the melt-blown polymer filaments onto the conveyer along a first direction, wherein the SAP dispenser is positioned and arranged to direct the SAP onto the melt-blown polymer filaments along a second direction, and wherein the second direction is at an angle relative to the first direction.[000251] Any of the system embodiments above can include a dispensing roller positioned to dispense a substrate nonwoven onto the conveyer, a dispensing roller positioned to dispense a cover nonwoven onto the nonwoven composite on the conveyer, a hot melt adhesive applicator positioned to apply a hot melt adhesive onto the cover nonwoven, or combinations thereof.[000252] Although the present embodiments and advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Claims

ATTY DOCKET: DSGI-1015WOCLAIMSWhat is claimed is:

1. A method of forming an absorbent composite, the method comprising: melt-blowing a first polymer to form a first melt-blown web comprising a plurality of filaments of the first polymer;directing the first melt-blown web as a continuous moving web toward a surface; directing a first stream of superabsorbent polymer particles to impact the first melt-blown web such that at least a portion of the superabsorbent polymer particles are dispersed in the first melt-blown web to form a first melt-blown composite, wherein in at least some of the superabsorbent particles penetrate the first melt-blown web to situate within the resulting first melt-blown composite; anddepositing the first melt-blown composite onto the surface.

2. The method of claim 1, wherein the first melt-blown web is directed toward the surface in a first direction, wherein the first stream of superabsorbent polymer particles are directed toward the first melt-blown web in a second direction, and wherein the second direction is at an angle relative to the first direction.

3. The method of claim 2, wherein the angle is controlled to reduce loss of the superabsorbent polymer particles upon impact of the superabsorbent polymer particles with the first melt-blown web, to reduce an amount of loose superabsorbent polymer particles in the composite material, or combinations thereof.

4. The method of claim 2, wherein the angle is from 80 degrees to 100 degrees.

5. The method of claim 1 , wherein the continuous moving web is an output of an extruder directed downwardly, and wherein the stream is directed to intersect the continuous moving wen at an angle less than 90 degrees from the horizontal and integrate the superabsorbent particles therewith in a resulting first melt-blown composite; andwherein, in the resulting first melt-blown composite, the filaments adhere with the superabsorbent particles to form a scaffolding structure about the superabsorbent particles.

6. The method of claim 1, wherein the surface is a surface of a substrate nonwoven.

7. The method of claim 6, comprising applying a cover nonwoven over the first melt-blown composite such that the first melt-blown composite is positioned between the cover nonwoven and the substrate nonwoven.

8. The method of claim 7, wherein the cover nonwoven is adhered to the first melt-blown composite via adhesive, ultra sonic bonding, or thermal bonding.ATTY DOCKET: DSGI-1015WO9. The method of claim 1, comprising directing a second stream of superabsorbent polymer particles to impact the first melt-blown web such that at least a portion of the superabsorbent polymer particles are distributed within the first melt-blown web to form the first melt-blown composite, wherein the second stream of superabsorbent polymer particles impact the first melt-blown web at a location that is upstream of the surface.

10. The method of claim 9, wherein the second stream of superabsorbent polymer particles impact the first melt-blown web at a location that is downstream of the first stream of superabsorbent polymer particles.

11. The method of claim 9, wherein the first stream of superabsorbent polymer particles impact a first side of the first melt-blown web, wherein the second stream of superabsorbent polymer particles impact a second side of the first melt-blown web, and wherein the first side is opposite the second side.

12. The method of claim 1, comprising directing a first stream of additive particles to impact the first melt-blown web such that at least a portion of the additive particles are distributed within the first melt-blown web to form the first melt-blown composite, wherein the first stream of additive particles impact the first melt-blown web at a location that is upstream of the surface.

13. The method of claim 1, comprising:melt-blowing a second polymer to form a second melt-blown web comprising a plurality of filaments of the second polymer;directing the second melt-blown web toward the surface; andcombining the second melt-blown web with the first melt-blown composite, forming a second melt-blown composite.

14. The method of claim 13, wherein the combining includes depositing the second melt-blown web onto the surface, and depositing the first melt-blown composite onto the second melt-blown web.

15. The method of claim 13, wherein the combining includes depositing the second melt-blown web onto the first melt-blown composite on the surface.

16. The method of claim 13, comprising directing a second stream of superabsorbent polymer particles to impact the second melt-blown web such that at least a portion of the superabsorbent polymer particles are distributed within the second melt-blown web, wherein the second stream of superabsorbent polymer particles impact the second melt-blown web at a location that is upstream of the surface.

17. The method of claim 16, wherein the superabsorbent polymer particles of the first stream are the same as the superabsorbent polymer particles of the second stream.

18. The method of claim 16, wherein the superabsorbent polymer particles of the first stream are different than the superabsorbent polymer particles of the second stream.ATTY DOCKET: DSGI-1015WO19. The method of claim 13, comprising directing a first stream of additive particles to impact the second melt-blown web such that at least a portion of the additive particles are distributed within the second melt-blown web, wherein the first stream of additive particles impact the second melt-blown web at a location that is upstream of the surface.

20. The method of claim 13, wherein the first polymer and the second polymer are the same.

21. The method of claim 13, wherein the first polymer and the second polymer are different.

22. The method of claim 13, comprising:melt-blowing a third polymer to form a third melt-blown web comprising a plurality of filaments of the third polymer;directing the third melt-blown web toward the surface; andcombining the third melt-blown web with the second melt-blown composite, forming a third melt-blown composite.

23. The method of claim 22, wherein, within the third melt-blown composite, the first melt-blown composite is positioned between the second and third melt-blown webs.

24. The method of claim 22, comprising directing a stream of superabsorbent polymer particles to impact the third melt-blown web such that at least a portion of the superabsorbent polymer particles are distributed within the third melt-blown web, wherein the stream of superabsorbent polymer particles impact the third melt-blown web at a location that is upstream of the surface.

25. The method of claim 22, comprising directing a stream of additive particles to impact the third melt-blown web such that at least a portion of the additive particles are distributed within the third melt-blown web, wherein the stream of additive particles impact the third melt-blown web at a location that is upstream of the surface.

26. The method of claim 1, wherein the first melt-blown web has a first surface and a second surface, wherein the first stream of superabsorbent polymer particles is directed to impact with the first surface, wherein impact of the first stream of superabsorbent polymer particles with the first surface opens a network of filaments of the first melt-blown web at the first surface, forming a gradient bulk density and gradient void volume in the first melt-blown web such that a void volume of the first melt-blown web is greater at the first surface than the second surface, and such that a bulk density of the first melt-blown web is less at the first surface than the second surface.

27. The method of claim 26, wherein impact of the first stream of superabsorbent polymer particles with the first melt-blown web results in a gradient distribution of theATTY DOCKET: DSGI-1015WOsuperabsorbent polymer particles within the first melt-blown web such that a population of the superabsorbent polymer particles positioned closer to the second surface have a smaller average particle size than a population of the superabsorbent polymer particles positioned closer to the first surface.

28. The method of claim 26, wherein the first melt-blown web forms a scaffolding structure at the first surface including filaments of the first melt-blown web that entangle the superabsorbent polymer particles.

29. The method of claim 26, wherein the first melt-blown web forms a retention structure at the second surface including filaments of the first melt-blown web that prevent passage of the superabsorbent polymer particles through the second surface.

30. The method of claim 1, wherein the first melt-blown web comprises a curtain of filaments of the first polymer.

31. The method of claim 30, wherein the filaments are entangled together.

32. The method of claim 1, wherein, at impact of the superabsorbent polymer particles with the first melt-blown web, the filaments of the first melt-blown web are at least partially molten and tacky.

33. The method of claim 1, wherein directing the first melt-blown web is a continuous web that is directed to the surface, and wherein the first stream is a continuous stream that is directed to impact with the first melt-blown web.

34. The method of claim 1, comprising cooling the first melt-blown composite.

35. The method of claim 1, wherein the continuous moving web is a heated web and upon impacting the heated continuous moving web, the superabsorbent particles begin to adhere to filaments of the first melt-blown web.

36. The method of claim 1, wherein:melt-blowing the first polymer to form the first melt-blown web includes extruding the plurality of filaments of the first polymer in a first hot air stream, wherein the first melt-blown web is directed toward the surface in the first hot air stream;the first stream of superabsorbent polymer particles is directed to impact the first melt-blown web in a second hot air stream; andthe second hot air stream intersects the first hot air stream upstream of the surface.

37. The method of claim 1, wherein directing the first stream of superabsorbent polymer particles includes directing the superabsorbent polymer particles from a venturi device.

38. The method of claim 37, wherein the superabsorbent polymer particles are mixed with a hot air stream in the venturi device.ATTY DOCKET: DSGI-1015WO39. The method of claim 1, wherein melt-blowing the first polymer includes hot air extruding the first polymer from an extruder.

40. The method of claim 1, wherein the superabsorbent polymer particles adhere to the filaments of the first melt-blown web without use of an adhesive.

41. The method of claim 1 , wherein the first melt-blown web is directed toward the surface via gravity.

42. The method of claim 1, wherein the surfaces is a surface of a conveyor belt, and wherein a speed of the conveyer belt is coordinated with a throughput of the first melt-blown web to affect a basis weight of the first melt-blown composite.

43. The method of claim 13, comprising directing a stream of additive particles to impact the first melt-blown web, the second melt-blown web, or both, such that at least a portion of the additive particles are distributed within one or both of the first and second melt-blown webs, wherein the stream of additive particles impacts the first and / or second melt-blown webs at a location that is upstream of the surface.

44. The method of claim 43, wherein the additive particles comprise polylactic acid (PLA) short fibers, polyethylene terephthalate (PET) hollow fibers, calcium carbonate fibers, omya fibers, perlite, pumice, zeolite, staple fibers, chitosan, collagen, PLA, polypropylene (PP), polyurethane (PU), polypropylene / polyethylene (PP / PE) bicomponent fibers, granules, wood pulp, cellulose acetate fibers, viscose fibers, cotton fibers, bamboo fibers, hemp fibers, micro-fibrillated cellulose (MFC), or thermally expandable microspheres.

45. The method of claim 43, wherein the additive particles include hydrophilic fibrillated nanofibers.

46. The method of claim 43, wherein the additive particles include acidic or basic water absorbent resin particles.

47. The method of claim 43, wherein the additive particles include wetting agents or flow promoters.

48. The method of claim 1, wherein the first polymer is melt-blown from an extruder to form the first melt-blown web, and wherein a distance between the extruder of the surface is from 40 to 80 cm.

49. The method of claim 1, wherein the first stream is directed from a nozzle, and wherein a distance between the nozzle and the first melt-blown web is from 4 to 8 cm.

50. The method of claim 1, wherein a throughput of the first melt-blown web is from 0.5 to 2 kg of the first melt-blown web per minute, and wherein a throughput of the first stream is from 9.6 to 38.6 kg of superabsorbent polymer particles per minute.ATTY DOCKET: DSGI-1015WO51. The method of claim 1, wherein the superabsorbent polymer particles are at ambient temperature when impacted with the first melt-blown web, and wherein the first melt-blown web is at a temperature ranging from 150°C to 250°C when impacted with the superabsorbent polymer particles.

52. The method of claim 1, wherein, upon impact between the superabsorbent polymer particles and the first melt-blown web, the superabsorbent polymer particles turbulently mix with the first melt-blown web.

53. The method of claim 1, wherein the superabsorbent polymer particles adhere or bonds with the first melt-blown web via tack.

54. The method of claim 1, wherein the superabsorbent polymer particles adhere or bonds with the first melt-blown web via van der Waals interactions.

55. The method of claim 1, wherein the method is an online process in which the first melt-blown composite is directed to an in-line a diaper manufacturing process.

56. The method of claim 1, wherein the method is an offline process in which the first melt-blown composite is collected subsequent use.

57. The method of claim 1, wherein the first melt-blown web has a basis weight of from 10 to 50 g / m2.

58. The method of claim 1, wherein the first melt-blown web has a thickness of from 0.05 mm to 0.50 mm.

59. The method of claim 1, where the first melt-blown composite has a SAP loading o from 100 to 700 g / m2.

60. The method of claim 1, where a layer of SAP in the first melt-blown composite has a thickness of from 0.1 mm to 1 mm.

61. The method of claim 1 , wherein a basis weight of the first melt-blown composite ranges from 200 to 800 g / m2.

62. The method of claim 1, wherein a thickness of the first melt-blown composite ranges from 0.30 mm to 2.50 mm.

63. The method of claim 1, wherein a density of the first melt-blown composite ranges from 300 to 800 kg / m3.

64. The method of claim 1, wherein the first polymer comprises a polyolefin.

65. The method of claim 64, wherein the polyolefin comprises polypropylene.

66. The method of claim 65, wherein the first polymer comprises an elastomer and the polypropylene.ATTY DOCKET: DSGI-1015WO67. The method of claim 65, wherein the first polymer comprises from 5 to 78 wt.%, of the polypropylene.

68. The method of claim 64, wherein the polyolefin comprise polyethylene.

69. The method of claim 1, wherein the first polymer comprise from 1 to 15 wt.% of a rheology modifier70. The method of claim 1, wherein the first polymer comprises from 2 to 20 wt.% of a wetting agent.

71. The method of claim 1, wherein the first polymer comprises from 20 to 90 wt.% of an elastomer.

72. The method of claim 1, wherein the first polymer comprises a block copolymer having a hard segment and a soft segment.

73. The method of claim 1, wherein the first polymer comprises a thermoplastic elastomer.

74. The method of claim 1, wherein the first polymer comprises a thermoplastic polyurethane.

75. The method of claim 1, wherein the filaments are hydrophilic, elastic, and absorbent.

76. The method of claim 1, wherein the first polymer comprises a thermoplastic polyurethane and a polyolefin.

77. The method of claim 76, wherein the polyolefin is polypropylene, and wherein the first polymer comprises from 10 to 50 wt.% of the polypropylene.

78. The method of claim 1, wherein the first stream of superabsorbent polymer particles includes a population of superabsorbent polymer particles have particle sizes ranging from about 45 microns to about 850 microns.

79. The method of claim 1, wherein melt blowing the first polymer comprises melting and extruding the first polymer from a die head of an extruder with a hot air stream.

80. The method of claim 1, wherein the first melt-blown composite is pulpless and fluffless.

81. The method of claim 1, wherein the first melt-blown composite lacks an adhesive.

82. The method of claim 2, wherein the angle is oblique.

83. The method of claim 1, wherein the first polymer is a thermoplastic polymer.

84. The method of claim 1, comprising increasing a hydrophilicity of the first polymer.ATTY DOCKET: DSGI-1015WO85. The method of claim 84, wherein increasing the hydrophilicity comprises adding a wetting agent to the first polymer.

86. A nonwoven composite, the nonwoven composite comprising:a first nonwoven web comprising a three-dimensional network of filaments, wherein the first nonwoven web has a first surface and a second surface, wherein the three-dimensional network of filaments has a gradient void volume such that a void volume at the first surface is greater than a void volume at the second surface, and wherein the three-dimensional network of filaments form a first scaffold structure at the first surface; anda first plurality of superabsorbent polymer particles dispersed within first nonwoven web, wherein the superabsorbent polymer particles are at least partially positioned within interstitial void volume of the first scaffold structure, and wherein the filaments of the first scaffold structure interlace, at least partially, about the superabsorbent polymer particles.

87. The nonwoven composite of claim 86, wherein the three-dimensional network of filaments form a first retention structure at the second surface.

88. The nonwoven composite of claim 86, wherein the superabsorbent polymer particles have a gradient size distribution with the nonwoven web such that first superabsorbent polymer particles are positioned closer to the first surface and second superabsorbent polymer particles are positioned closer to the second surface, and wherein the first superabsorbent polymer particles are larger than the second superabsorbent polymer particles.

89. The nonwoven composite of claim 86, comprising a second nonwoven web comprising a three-dimensional network of filaments and having a first surface and a second surface, wherein the first surface of the second nonwoven web is coupled with the first surface of the first nonwoven web such that superabsorbent polymer particles are positioned between the second surface of the first nonwoven web and the second surface of the second nonwoven web.

90. The nonwoven composite of claim 89, comprising:a third nonwoven web comprising a three-dimensional network of filaments, wherein the third nonwoven web has a first surface and a second surface, wherein the three-dimensional network of filaments has a gradient void volume such that a void volume at the first surface is greater than a void volume at the second surface, and wherein the three-dimensional network of filaments form a second scaffold structure at the first surface; anda second plurality of superabsorbent polymer particles dispersed within third nonwoven web, wherein the superabsorbent polymer particles are at least partially positioned within interstitial void volume of the second scaffold structure, and wherein the filaments of theATTY DOCKET: DSGI-1015WOsecond scaffold structure interlace, at least partially, about the superabsorbent polymer particles;wherein the first surface of the third nonwoven web is coupled with the second surface of the second nonwoven web such that the superabsorbent polymer particles of the nonwoven composite are positioned between the second surface of the first nonwoven web and the second surface of the third nonwoven web.

91. The nonwoven composite of claim 86, comprising a substrate nonwoven coupled with the first nonwoven web.

92. The nonwoven composite of claim 91, comprising a cover nonwoven coupled with the first nonwoven web such that the first nonwoven web is positioned between the cover nonwoven and the substrate nonwoven.

93. The nonwoven composite of claim 90, wherein the first plurality of superabsorbent polymer particles are the same as the second plurality of superabsorbent polymer particles.

94. The nonwoven composite of claim 90, wherein the first plurality of superabsorbent polymer particles are different than the second plurality of superabsorbent polymer particles.

95. The nonwoven composite of claim 86, comprising one or more additives dispersed within the he first nonwoven web such that at least a portion of the additives are distributed within the first nonwoven web.

96. The nonwoven composite of claim 86, wherein the filaments entangle the superabsorbent polymer particles within the scaffold structure.

97. The nonwoven composite of claim 95, wherein the additives comprise polylactic acid (PLA) short fibers, polyethylene terephthalate (PET) hollow fibers, calcium carbonate fibers, omya fibers, perlite, pumice, zeolite, staple fibers, chitosan, collagen, PLA, polypropylene (PP), polyurethane (PU), polypropylene / polyethylene (PP / PE) bicomponent fibers, granules, wood pulp, cellulose acetate fibers, viscose fibers, cotton fibers, bamboo fibers, hemp fibers, micro-fibrillated cellulose (MFC), or thermally expandable microspheres.

98. The nonwoven composite of claim 95, wherein the additives include hydrophilic fibrillated nanofibers.

99. The nonwoven composite of claim 95, wherein the additives include acidic or basic water absorbent resin particles.

100. The nonwoven composite of claim 95, wherein the additives include wetting agents or flow promoters.

101. The nonwoven composite of claim 86, wherein the superabsorbent polymer particles adhere or bond with the filaments via tack.ATTY DOCKET: DSGI-1015WO102. The nonwoven composite of claim 86, wherein the superabsorbent polymer particles adhere or bond with the fdaments via van der Waals interactions.

103. The nonwoven composite of claim 86, wherein the first nonwoven web has a basis weight of from 10 to 50 g / m2.

104. The nonwoven composite of claim 86, wherein the first nonwoven web has a thickness of from 0.05 mm to 0.50 mm.

105. The nonwoven composite of claim 86„ where the first nonwoven web has a SAP loading o from 100 to 700 g / m2.

106. The nonwoven composite of claim 86, where a layer of SAP in the first nonwoven web has a thickness of from 0.1 mm to 1 mm.

107. The nonwoven composite of claim 86, wherein a basis weight of the nonwoven composite ranges from 200 to 800 g / m2.

108. The nonwoven composite of claim 86, wherein a thickness of the nonwoven composite ranges from 0.30 mm to 2.50 mm.

109. The nonwoven composite of claim 86, wherein a density of the nonwoven composite ranges from 300 to 800 kg / m3.

110. The nonwoven composite of claim 86, wherein the filaments of the first nonwoven web comprise a polyolefin filaments.

111. The nonwoven composite of claim 110, wherein the polyolefin comprises polypropylene.

112. The nonwoven composite of claim 86, wherein the filaments of the first nonwoven web comprise an elastomer and a polypropylene.

113. The nonwoven composite of claim 112, wherein the filaments of the first nonwoven web comprise from 5 to 78 wt.%, of the polypropylene.

114. The nonwoven composite of claim 86, wherein the filaments of the first nonwoven web comprise polyethylene.

115. The nonwoven composite of claim 86, wherein the filaments of the first nonwoven web comprise from 1 to 15 wt.% of a rheology modifier116. The nonwoven composite of claim 86, wherein the filaments of the first nonwoven web comprise from 2 to 20 wt.% of a wetting agent.

117. The nonwoven composite of claim 86, wherein the filaments of the first nonwoven web comprise from 20 to 90 wt.% of an elastomer.

118. The nonwoven composite of claim 86, wherein the filaments of the first nonwoven web comprise a block copolymer having a hard segment and a soft segment.ATTY DOCKET: DSGI-1015WO119. The nonwoven composite of claim 86, wherein the filaments of the first nonwoven web comprise a thermoplastic elastomer.

120. The nonwoven composite of claim 86, wherein the filaments of the first nonwoven web comprise a thermoplastic polyurethane.

121. The nonwoven composite of claim 86, wherein the filaments of the first nonwoven web are hydrophilic, elastic, and absorbent.

122. The nonwoven composite of claim 86, wherein the filaments of the first nonwoven web comprise a thermoplastic polyurethane and a polyolefin.

123. The nonwoven composite of claim 122, wherein the filaments comprise from 10 to 50 wt.% of the polypropylene.

124. The nonwoven composite of claim 86, wherein the superabsorbent polymer particles includes a population of superabsorbent polymer particles have particle sizes ranging from about 45 microns to about 850 microns.

125. The nonwoven composite of claim 86, wherein the nonwoven composite is pulpless and fluffless.

126. The nonwoven composite of claim 86, wherein the nonwoven composite lacks an adhesive.

127. The nonwoven composite of claim 86, wherein the filaments of the first nonwoven web comprise a thermoplastic polymer.

128. A system for making a nonwoven composite, the system comprising:a melt-blowing extruder positioned to provide melt-blown polymer filaments;a conveyer positioned to receive the melt-blown polymer filaments from the meltblowing extruder; anda SAP dispenser positioned to direct SAP onto the melt-blown polymer filaments exiting the melt-blown extruder and upstream of the conveyer to form a nonwoven composite.

129. The system of claim 128, wherein the melt-blowing extruder is positioned and arranged to direct the melt-blown polymer filaments onto the conveyer along a first direction, wherein the SAP dispenser is positioned and arranged to direct the SAP onto the melt-blown polymer filaments along a second direction, and wherein the second direction is at an angle relative to the first direction.

130. The system of claim 129, wherein the angle is from 80 degrees to 100 degrees.

132. The system of claim 128, comprising a dispensing roller positioned to dispense a substrate nonwoven onto the conveyer.ATTY DOCKET: DSGI-1015WO133. The system of claim 132, comprising a dispensing roller positioned to dispense a cover nonwoven onto the nonwoven composite on the conveyer.

134. The system of claim 133, comprising a hot melt adhesive applicator positioned to apply a hot melt adhesive onto the cover nonwoven.

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