JP2020524017A - Absorbent core assembly, ergonomic disposable absorbent underwear utilizing same, and method of making same - Google Patents

Abstract

Disposable underwear including an absorbent core assembly and methods of making the same are disclosed. The undergarment includes a body that holds a core assembly. The body includes a front portion, a crotch portion, and a rear portion. The core assembly is installed in the crotch part, and the part straddles the front part and the rear part. A large number of closely spaced elastic threads extend across the entire width of the front and back of the undergarment. The elastic thread is interrupted in the area of the core assembly. The core assembly includes a first section of a slow acting but high absorbency SAP in its pocket and a second section of an underlayer of a fast acting but low absorbency SAP in its pocket.

Description

The present invention relates generally to disposable absorbent products, and more specifically to adult disposable absorbent undergarments, absorbent core assemblies for same, and disposable core assemblies and disposable disposable absorbent underwear, such as adult disposable absorbent underwear. Regarding the method of making an absorbent product, each undergarment includes an absorbent core assembly.

Various disposable underwear are currently marketed by various manufacturers for use by adults with incontinence problems. An example of such a product is men's and women's pants sold by the Kimberly-Clark Corporation under the Depend(R) trademark. The Depend® product utilizes a body with an absorbent core attached to the crotch region of the body. The body itself is a colored non-woven fabric having about 57 strands of white spandex elastic yarns laminated between layers of non-woven spunbond fabric to provide elasticity to hold the underwear close to the wearer's body. Equipped with. Since the spacing between the elastic fibers is relatively wide, for example 6 to 7 mm, the main body has a slightly pleated appearance.

Other manufacturers offer similar types of underwear that utilize the body to hold the absorbent core, which is designed to fit the undergarment to the body for concealment and wearer comfort. Of a plurality of laterally extending elastic threads or filaments. For example, Proctor & Gamble offers incontinence underwear under the Always(R) trademark. The product also utilizes a body comprising about 57 relatively widely spaced, transversely extending strands of white spandex elastic yarn sandwiched between two layers of non-woven spunbond fabric. The body is fitted with an absorbent core and includes six additional colored elastic threads on the back of the body that serve as indicators on the back side of the product. Like the Depends® product, the Alwayss® product has a slightly pleated appearance.

Livedu USA, Inc. (Livedo, USA) offers incontinence pants under the trademark LiveDry™. The product is a panel laminated between two layers of white spunbond fabric, with approximately 40 wide, laterally-extending, laterally extending spandex elastic strands, and a product that serves as an indicator on the back of the product. Utilizes a body with an additional eight colored elastic spandex on the back of the. Like the Depend(R) and Always(R) products, the LiveDry(R) product has a slightly pleated appearance.

Kimberly Clark Corporation manufactures two other adult incontinence products under the names Depend® Silhouette and Depend® Realfit. Both products employ materials in the form of elastic meltblown film fabrics, which are difficult to process, more costly and limited in stretchability.

In addition, many current adult disposable absorbent products utilize what is known as a mixture of fiberized bleached wood fluff pulp and SAP (Super Absorbent Polymer) for the absorbent core. At low ratios of SAP to pulp of 30% or less, the core mixture may or may not be wrapped in absorbent tissue so that the SAP does not fall apart or fall out of the core. .. At levels as high as 50% SAP or higher, the core must be wrapped to prevent loose SAP from being shaken off. A core adhesive may also be added to prevent the heavier SAP particles from separating from the fluff pulp fibers. The pulp fibers in these products require rapid control of bodily fluid exudates until the SAP can desorb the fluff fibers to prepare them for subsequent exudates. For adults, exudate volumes easily exceed 300 ml or more and are excreted at a rate equal to or less than that excreted by infants over a period of more than 70 seconds.

A significant problem with current absorbent products containing wood fluff pulp or even wrapped with tissue or airlaid is that in all cases, as a result of its structure, the body will not be able to accept the excreted fluid after the core has received it. Feeling wet. To address this wetness, almost all current absorbent product designs employ a synthetic fiber spacing layer over the "wet core" in an attempt to create a "dryer" layer. ing. This synthetic spacing layer is often referred to as the "fluid transfer layer," "fluid acquisition layer," or "acquisition distribution layer (ADL)," which is typically much smaller than the core it covers. , The edges of the core remain exposed. Moreover, regardless of their design goals, such fluid acquisition layers work only to a limited extent. In this regard, as exudate exits the body at 37 degrees Celsius (98 degrees Fahrenheit), it rapidly drops to about 32 degrees Celsius (about 90 degrees Fahrenheit) as it enters the core of the absorbent product. This creates a cooling effect on contact with the skin that can increase during wear time. If left for a long time, the wet product will reach thermal equilibrium, equilibrating somewhere between room temperature and about 32 degrees Celsius (about 90 degrees Fahrenheit), depending on ambient temperature and the clothing worn. Become. This difference can be exacerbated depending on the thermal conductivity of the material chosen to absorb the exudate. However, in all cases, current wood pulp fluff absorbent products make the skin feel wet and/or cold the longer the product is worn.

Current state-of-the-art product designs for synthetic absorbent cores are based on a synthetic continuous fiber matrix with SAP sandwiched between layers. For example, a polypropylene tow fiber similar to the tow used to make tobacco filters was chosen. This material is purchased in a continuous form and is withdrawn from the box and fed into an air trumpet or similar device or the like to expand the fiber tow matrix. The SAP particles are then mixed together and the fiber SAP matrix is sprayed with the adhesive and the entire matrix is wrapped to give what is known in the state-of-the-art so-called "Palpress" core technology. This type of core has the major limitation of slow absorption rate. The rate is highly dependent on the SAP chosen and the type and amount of adhesive required to deposit the SAP on the tow fiber matrix. For example, if sufficient adhesive is provided to ensure that the SAP remains in its desired position within the core, the adhesive may limit the absorbent swelling of the SAP due to the portion overlying the SAP particles. .. If less adhesive is used, swelling by SAP and absorption of exudate may be enhanced, but there is a risk of SAP particles falling from that position in the core to the bottom of the crotch area and excreted. Sometimes the crotch part becomes heavier and more wet, and there is less absorbent at the ends.

Another example of current pulpless core technology is to adhere SAP to the inside of a backsheet or topsheet or body facing sheet. This binding process may limit the SAP's full swelling and utilization when absorbing exudates. When combined with such materials, SAP is also added in continuous rows to ensure space for the fluid to flow unobstructed. Alternatively, the SAP may be blended with similarly sized groundwood fibers to enhance fluid movement in this inefficient design.

Due to current SAP limitations, one has to choose between high absorption capacity with the drawback of slow speed or high speed SAP with poor absorption capacity. When current SAPs are mixed, fast-acting SAPs can swell very rapidly and "gel block" slow-acting but high-absorption capacity SAPs. When gel blocking occurs, high volume SAPs limit or even prevent desorption of faster but lower volume SAPs.

In the past, cellulose acetate fiber cores with a single SAP were developed and marketed to have a non-SAP version. Current polypropylene filament tow technology has also been used for absorbent cores. In this regard, such polypropylene tow cores currently in use on the market utilize circular or oval shaped homopolymer polypropylene fibers which have minimal resistance to fluid flow through the SAP/tow fiber matrix. And thereby minimizes the residence time of the fluid absorbed by the SAP.

While the above-mentioned prior art is generally suitable for its intended purpose, it is still desirable from that perspective that it is comfortable, thin, aesthetically pleasing, and highly concealable underwear of outer garments. In, the ability to absorb the excreted liquid quickly, easily and effectively without leaking. Therefore, there is a need for disposable underwear that addresses these needs.

The present invention addresses these needs by providing an absorbent core assembly (hereinafter also referred to as "composite absorbent core") and body for underwear (eg, adult pants) that overcomes the deficiencies of the prior art. Correspond. The absorbent core assembly exhibits the ability to absorb drained liquids quickly, easily and effectively without leaking, making the assembly comfortable, thin, aesthetically pleasing and highly concealable under outer garments. Wear inside the body. In particular, the body includes a much larger number of laterally extending elastic strands, which are more closely spaced from each other, thus providing a significantly improved fit to the wearer's body while at the same time providing prior art techniques. Provides a flatter appearance than the pleated look of incontinence underwear. The absorbent core assembly is composed of two sections of SAP for fast and reliable absorption of the excreted liquid without leakage. One section of the core, which is placed against the body of the wearer, includes a plurality of slow acting but highly absorbent free SAP partially filled pockets. The other section of the core is oriented away from the wearer's body and includes a plurality of fast acting but low absorbency, partially filled pockets of free SAP. In this configuration, the liquid excreted in the core is first rapidly absorbed by the fast acting SAP section, where the section with the slow acting but highly absorbent SAP desorbs the section with the fast acting SAP. Thus, the excreted liquid is surely contained in the liquid and the leakage from the core is prevented.

There is still much desire in the currently realized production of disposable absorbent products. In this regard, the most common process for producing absorbent disposable products with absorbent cores, which has been and has been used for the past 45 years, is the roll of bleached softwood timber produced in a paper mill. Start with pulp. Deforestation of mature trees to supply pulpwood to these huge mills. It should be noted that each adult tree can absorb about 4 tonnes of carbon dioxide per year. After the trees have been cut down, saplings are usually planted and it takes 20 to 40 years before they become mature. Paper mills are extremely large, spend a lot of energy processing wood, and chemicals such as chlorine or chlorine dioxide are very toxic but necessary for the bleaching process. Currently, building a paper mill typically costs between about $500 million and $1 billion. This limits the construction of new paper mills. This also provides a tremendous incentive for current manufacturers to stay or stop using these existing large-scale capital, land (forest) and workforce investments.

These bleached absorbent pulp rolls are then shipped to absorbent underwear manufacturers, also known as converters. Thereafter, the bleached wood pulp roll is processed by a fiberizing hammer mill in the production processing line to fiberize the bleached softwood absorbent pulp into discrete fibers. From a hammer mill, these fibers are conveyed by air under the system using a vacuum to a continuous tissue layer on top of a screen-like material, or with a pocket on a rotating drum that is pulled into a pocket by vacuum. Convey to the shape screen. These hammer mills require a high level of energy to rotate the hammer at about 10,000 revolutions per minute and typically require a 720 volt power supply, making such equipment a large voltage and amperage power supply. Limited to the heavy industrial transmission system area. The hammer mill and subsequent support processes also cost about $1 million or more. Some processes currently in use have two such $1 million hammer mill processes. In addition, these processes require large volumes of compressed air, vacuum, and large scale air filtration systems to remove large amounts of dust. This is necessary for a single absorbent product processing machine as well as the entire factory. If more than one such machine is involved, substantially more equipment is required. Everything adds to the cost of the $1 million hammer mill system. The noise of these hammer mills requires operators to wear hearing protection to counter some of the noise. Hearing protectors can also prevent operators from effectively communicating with each other, which can contribute to a business accident.

Since the 1980s, such absorbent product processing systems have added some amount of superabsorbent polymer, commonly referred to as SAP. Chemically, this is polymerized polyacrylic acid partially neutralized with sodium hydroxide. Other additives may also be added in the polymerization process or locally during the drying process to highlight the desired differences. This SAP material increases the total capacity of the absorbent system without the addition of additional fiberized wood pulp. The advantage of SAP is that it helps desorb or withdraw moisture from the fiberized wood pulp in order to increase the dryness of such systems. A drawback of SAP is its slow absorption characteristics, which causes such absorbent systems to require the fiberized wood pulp to control the rate of fluid insult. In some cases, SAP is further modified to increase the absorption rate, which reduces the absorption capacity and causes gel block problems. Gel blocking is a problem in that the outer SAP particles absorb fluid and swell, blocking or blocking the fluid from reaching the inner SAP particles. The SAP particles are also carried by air into the fiberized pulp stream to produce the desired ratio of fiberized wood pulp to SAP (often referred to as the pulp/SAP ratio). Higher percentages, above 30% and above, may require tissue wrap paper. In contrast, if the amount of SAP is lower or the ratio is less than 30%, tissue wrap paper may not be needed. Generally, no additives or trace amounts of fog water or mineral oil and the like are added to the hammer mill to improve processability. In some cases, a small amount of absorbent core adhesive may be used to add integrity to the fluff/SAP absorbent core. This has the drawback of impeding process flow and has not been universally accepted or utilized for this type of structure.

Some absorbent product manufacturers have used dual forming fluff pulp systems to overcome some of the problems mentioned above. In particular, some modifications of such existing pulp/SAP absorbent product production systems include the use of dual or dual fiberization systems. In such a case, the absorbent core is composed of two layers, usually with SAP in both layers. This will serve for marketing and promotion claiming "dual core". If this incorporates two similar pulp/SAP ratios, there would be a slight improvement in providing additional consistency to the absorbent core. In some circumstances, the manufacture of such absorbent cores may choose to use a different pulp for the bodyside layer than the bodyside layer. In some cases it can also be a highly crosslinked cellulosic pulp "curly fiber", or similar materials are usually found in the bodyside layer. Also, in certain other circumstances, the manufacturer may add higher levels of SAP to the bodily layer to promote dryness, depending on the layer away from the body, to control the rate of absorption. Sometimes choose. This only results in a slight increase in dryness and is also known as "rewet" or wetback on the body. In this structure, the total capacity or capacity depends on the total amount of SAP, fluff pulp and tissue, and their intrinsic capacity, regardless of structure.

In all the cases referred to above, these processes require large vacuum and dust collection systems as well as large, noisy, fiberizing systems that consume large amounts of energy. As mentioned above, adding a cost of at least $1 million or more to such a system for each drum former not only increases the total cost, but also for both machine operators and others in the factory. Requires a solid hearing protector to protect the hammer mill and the supporting air handling system from loud noise hearing damage. In all referenced situations, the absorbent product contains fiberized wood pulp, which controls the rate of absorbent insult from the wearer's body. Normal excretion from the body is about 150 to 250 ml in about 70 to 90 seconds. SAP itself does not absorb fluid well at such high rates. Therefore, fiberized fluff pulp is needed to control the initial velocity.

Other alternative absorbent cores and processes have been proposed. One such approach in an attempt to improve the thinness of absorbent cores, SAP-containing airlaid absorbent cores, has been made. Airlaid absorbers are usually composed of fibrous wood pulp mixed with up to 70% SAP and are adhesively or thermally bonded and compressed into a cardboard-like material. SAP-free airlaids are sold as premium or expensive disposable paper napkins or the like. Although such absorbent cores have a better thinness than pulp/SAP absorbent cores, they bond under pressure to thin the absorbent core, which inevitably results in slower absorption rates and air laid. The total capacity per gram is reduced. Moreover, the cost of this type of approach is increased due to the energy required to heat set or bond the structures together. Airlaid cores are also typically manufactured in another facility and shipped to a processing facility, which also adds to the cost. The lack of absorption rate has delayed the introduction of such products to the market. Hybrid products with a single layer of airlaid material are found above or below a standard pulp/SAP absorbent core to provide marketing differences.

Another alternative absorbent core produced between approximately 2003 and 2005 was an absorbent core composed of cellulose acetate fibers wrapped with a heavy SAP mixed with free SAP. .. The advantage of such an absorbent core is that it is not as insulating and warm as products made with cellulose fluff pulp and is therefore comfortable. Disadvantages are absorption rate and absorption rate. Such systems are not fast enough to handle adequate absorbent waste from infants or adults. The product sold using this structure was a Parent's Choice Protective Underwear sold by Walmart, Inc. from approximately 2003 to 2005. This was an absorbent pre-product for toilet training for slight leaks and was therefore a suitable product for children's pant diapers intended for single use only. This product was known to have the desired low thermal insulation compared to products containing fibrous cellulosics. Children well known to take off typical pulp-based pants-type diapers such as absorbent underwear due to uncomfortable warmth to the body, these products did not take off. Another variation of this product is the baby diaper produced in the Middle East by RK Beaufort, which incorporates polypropylene filaments instead of cellulose acetate fibers to reduce costs. These products were highly compressible as compared to standard fibrous wood pulp/SAP, making these products desirable for reduced shipping costs. However, its absorption rate is largely dependent on the SAP absorption rate, and the SAPs used in these structures have a vortex time of greater than 60 seconds, making them suitable for retaining normal rapid excretion from the body. Not not. Therefore, these baby diapers have relied on a lot of tight gasketing on their body to hold the loose liquid in the diaper until the SAP swells and can begin to absorb liquid.

Another variation in designing absorbent cores involves incorporating SAP-containing foams. However, these cores are unacceptable for urine applications because they lose structural integrity when the foam is wet.

Foam/SAP products are well suited for sanitary pads, as the menstrual flow is typically around 5 grams, not the 250 to 500 grams or more of urine normally required for infant or adult incontinence absorbent products. It has been.

Another approach to structuring the absorbent core involves the system developed by Dr. Susumu Suzuki of the Japan Absorbent Technology Institute (known as Japan Absorbent Technology Institute (JATI)). In its structuring, Dr. Suzuki crushed the pulp much finer than it could with a hammer mill to fiberize a sheet of wood pulp. Both particle sets are adhered to a backsheet or other material with similar particle size compared to SAP particles. This produces a very thin absorbent core. However, the resulting absorbent core is still unable to control the rate of absorbent insult due to the slowness of SAP, and is predicted based on the rate of adhesive to delaminate from SAP particles. In addition, the addition of additives and the additional processing required to grind the wood pulp into smaller sizes dramatically increases costs.

The aforementioned environmental impact issues, hearing safety and high capital costs have prevented new manufacturers from entering the absorbent product industry. Also, due to large investments, old contracts, processes, and equipment being invested, current manufacturers have resisted changing existing established processes. This is the situation for the past 45 years.

Thus, there is also a need for a method for producing absorbent disposable underwear and/or composite absorbent cores that overcomes the shortcomings of the prior art. The present invention addresses that need by providing a method of making an undergarment and a composite absorbent core for use in the undergarment that overcomes the shortcomings of the prior art.

One aspect of the invention is a disposable absorbent undergarment that is configured for human wear. The undergarment comprises a body and an absorbent core assembly configured to absorb fluid from a person.
The absorbent core assembly has a predetermined width. The body comprises a sheet of non-woven breathable material in the form of a cloth. The seat has an inner surface, a front portion, a back portion, and an intermediate portion positioned between the front portion and the back portion. The front portion has an upper front edge, a pair of front side edges, and a plurality of elastic threads, and the plurality of elastic threads extend parallel to the upper front edge and are parallel to each other from one of the pair of front side edges. It extends to the other of the pair of front side edges. The back portion has an upper back edge, a pair of back side edges, and a plurality of elastic threads, and the plurality of elastic threads extend parallel to the upper back edge and are parallel to each other. To the other of the pair of dorsal edges. The intermediate portion has a pair of central side edges and a plurality of elastic threads, the plurality of elastic threads extending parallel to the upper front edge and the upper back edge, and parallel to each other of the pair of central side edges. It extends from one to the other of the pair of center side edges. Each of the front side edges is fixed to the back side edge. Each of the pair of central sides includes an ergonomically shaped recess that defines each leg opening for a human. The recesses are spaced from each other by a distance greater than the predetermined width of the absorbent core assembly. The absorbent core assembly includes the core on the inner surface of the body at the intermediate portion between the leg openings so that the undergarment does not collapse or buckle when the person wears the core. An undergarment secured using a plurality of threads of the plurality of elastic threads of the intermediate portion of the absorbent core assembly that are divided into separate sections at locations.

In a preferred aspect of the undergarment of the present invention, the plurality of elastic threads of the front portion extend from a point closely adjoining the upper front edge to the intermediate portion and are closely spaced from each other, where the front portion is Has a minimal pleated appearance, wherein the plurality of elastic threads of the back section extend from a point closely adjacent to the upper back edge to the intermediate section and are closely spaced from each other, where The back has a minimal pleated appearance.

In another preferred aspect of the underwear of the present invention, the spacing between adjacent elastic threads is about 5 mm.
In another preferred aspect of the undergarment of the present invention, the elastic thread is colored so that it can be easily seen from the outer surface of the undergarment.

In another preferable aspect of the underwear of the present invention, the underwear includes a waistband portion adjacent to the upper front edge and the upper back edge. The waistband portion includes a plurality of waistband elastic threads extending parallel to the upper front edge and the upper back edge. The waistband elastic yarn has a greater degree of tension or elasticity than the elastic yarn in the portion of the body between the waistband portion and the crotch portion.

In another preferred aspect of the underwear of the present invention, the elastic yarn of the portion of the body between the waistband portion and the crotch exhibits a tension or stretch gradient that decreases toward the crotch. ..

In another preferred aspect of the undergarment of the present invention, the tension or stretch gradient comprises at least three zones of different tension or stretch.
In another preferred aspect of the undergarment of the present invention, the absorbent core assembly comprises a first section and a second section. The first section is formed from at least one layer of porous material configured to allow movement of liquid. The at least one layer of the porous material of the first section is quilted to form a plurality of first pockets. Each of the first pockets is partially filled with slow acting but high absorption capacity of free SAP. The second section is installed below the first section and has a predetermined width and length. The second section is formed from a layer of porous material configured to allow movement of liquid. The porous material of the second section is quilted to form a plurality of second pockets. Each of the second pockets is partially filled with fast acting but low absorption capacity of free SAP. The first section of the absorbent core assembly and the second section of the absorbent core assembly are in fluid communication with each other and the first section of the absorbent core assembly faces the perineal area of a person. Whereas the fluid formed by the person forming the body facing side flows into the fast acting SAP and the slow acting SAP, the fluid being absorbed quickly and rapidly by the fast acting SAP, The undergarment of claim 1, wherein the slow acting SAP desorbs or removes fluid from the fast acting SAP and absorbs the fluid itself.

In another preferred aspect of the undergarment of the present invention, the core comprises a fluid acquisition layer disposed on the first section of the core.
In another preferred aspect of the undergarment of the present invention, the volume of at least some SAPs of said first pocket is in the range of about 25 to 35 percent of the volume of said first pocket, and at least some of said second pockets. The SAP volume is within the range of about 20 to 30 percent of the volume of the second pocket.

In another preferred aspect of the underwear of the present invention, the first section of the core has a predetermined width and length, and the second section of the core has a predetermined width and length. And the core comprises an intermediate nonwoven fluid transfer layer (eg, airlaid material or the like) having a predetermined width that is less than the predetermined width of the first and second sections. The intermediate nonwoven fluid transfer layer is located between the first section and the second section to facilitate fluid transfer between the first section and the second section.

In another preferred aspect of the undergarment of the present invention, the first section comprises a first layer of porous material and a second layer of porous material. Each of the first layer and the second layer is configured to allow movement of liquid. The plurality of first pockets are formed in the first layer and the plurality of first pockets are formed in the second layer by being quilted by the fixedly attached fixing line. Each of the first pockets is partially filled with slow acting but high absorption capacity of free SAP.

Another preferred aspect of the undergarment of the present invention is an absorbent core comprising a first section and a second section. The first section is formed from at least a first layer and a second layer. Each of the first layer and the second layer is formed of a porous material configured to allow movement of a liquid and is quilted by a fixedly attached fixation line to provide a plurality of layers to the first layer. A plurality of first pockets are formed in the first pocket and the second layer. Each of the first pockets is partially filled with slow acting but high absorption capacity of free SAP, and the volume of at least some SAP in the first pocket of the first layer is: Is in the range of about 25 to 35 percent of the volume of the first pocket of the first layer, and the volume of at least some SAPs of the first pocket of the second layer is greater than the volume of the first pocket of the first layer. Within the range of about 80 to 120 percent of the volume or amount of SAP in and within the range of 25 to 35 percent of the volume or volume of the first pocket of the second layer. The first section forms a body-facing side that is placed facing the perineal area of the person. The second section is located below the first section and is in fluid communication with the first section. The second section has a predetermined width and length. The second section is formed from a layer of porous material configured to allow movement of liquid. The layers of the second section are quilted to form a plurality of second pockets. Each of the second pockets is partially filled with fast acting but low absorption capacity of free SAP, and the volume of at least some of the SAPs in the second pockets is equal to the volume of the second pockets. Within about 20 to 30 percent. The core is configured such that fluid excreted by a person flows into the first fast acting SAP and the slow acting SAP, while the fluid is quickly and rapidly absorbed by the fast acting SAP. The slow acting SAP desorbs or removes fluid from the fast acting SAP and absorbs the fluid itself.

In one aspect of the absorbent core, the first section is formed from a porous material configured to allow movement of fluid and is quilted by a fixedly attached fixation line to the third layer. A third layer forming a plurality of first pockets, wherein the volume of at least some SAPs of the first pockets of the third layer is the volume of SAPs in the first pockets of the first layer or In the range of about 80 to 120 percent of the amount and in the range of 25 to 35 percent of the volume or volume of the first pocket of the third layer.

Another preferred aspect of the present invention is an absorbent core comprising a first section and a second section. The first section is formed from at least a first layer and a second layer. Each of the first layer and the second layer is formed of a porous material configured to allow movement of a liquid and is quilted by a fixedly attached fixation line to provide a plurality of layers to the first layer. A plurality of first pockets are formed in the first pocket and the second layer. Each of the first pockets is partially filled with slow acting but high absorption capacity of free SAP, the first section SAP having a "vortex time" in the range of about 30 to 90 seconds. have. The first section forms a body-facing side that is placed facing the perineal area of the person. As known to those skilled in the art, the term "vortex time" is the time until SAP mixed with water in a container forms a gel by a rotary stirrer and stops the rotary stirrer. The second section is installed below the first section. The second section is in fluid communication with the first section. The second section has a predetermined width and length. The second section is formed from a layer of porous material configured to allow movement of liquid. The layers of the second section are quilted to form a plurality of second pockets. Each of the second pockets is partially filled with a fast acting but low absorption capacity of free SAP and the second section SAP has a SAP of about 3 to 20 seconds, preferably less than 10 seconds. Have vortex time. The ratio of the slow acting SAP to the fast acting SAP vortex time is in the range of about 6:1 to 3:1. The core is configured such that fluid excreted by a person flows into the first fast acting SAP and the slow acting SAP, while the fluid is quickly and rapidly absorbed by the fast acting SAP. The slow acting SAP desorbs or removes fluid from the fast acting SAP and absorbs the fluid itself.

In a preferred embodiment of the absorbent core, the first section is formed from a porous material configured to allow the movement of fluid and is quilted by a fixedly attached fixation line to provide the third layer. A third layer forming a plurality of first pockets, each of the first pockets of the third layer being partially filled with a slow acting but free SAP of high absorption capacity. There is.

Another preferred aspect of the present invention is an absorbent core having a longitudinal axis and having a first section and a second section. The first section is formed from at least one layer of porous material configured to allow movement of liquid and is quilted by a fixedly attached fixation line to provide a plurality of layers to the at least one layer. A first pocket is formed. Each of the first pockets is partially filled with slow acting but high absorption capacity of free SAP. Each of the first pockets is a diamond shape having a first pair of diametrically opposite corners and a second pair of diametrically opposite corners, the first pocket having the first pair of diametrically opposite corners parallel to the longitudinal axis. Oriented to extend to. The first section forms a body-facing side that is placed facing the perineal area of the person. The second section is installed below the first section. The second section is in fluid communication with the first section. The second section is formed from a layer of porous material configured to allow movement of liquid. The layers of the second section are quilted to form a plurality of second pockets. Each of the second pockets is partially filled with fast acting but low absorption capacity of free SAP. Each of the second pockets is diamond-shaped having a first pair of diametrically opposite corners and a second pair of diametrically opposite corners, the second pocket having the first pair of diametrically opposite corners parallel to the longitudinal axis. Oriented to extend. The core is configured such that fluid excreted by a person flows into the fast acting SAP and the slow acting SAP in a tortuous path created by the orientation of the diamond-shaped pockets with respect to the longitudinal axis. Whereas the fast acting SAP is quickly and rapidly absorbed, the slow acting SAP desorbs or removes fluid from the fast acting SAP and absorbs the fluid itself.

In a preferred embodiment of the absorbent core, the first section comprises a first layer and a second layer. Each of the first layer and the second layer is formed of a porous material configured to allow movement of a liquid and is quilted by a fixedly attached fixation line to provide a plurality of layers to the first layer. A plurality of first pockets are formed in the first pocket and the second layer. Each of the first pockets of each of the first layer and the second layer is a diamond shape having a first pair of diametrically opposite corners and a second pair of diametrically opposite corners. The first pocket of the layer is oriented such that the diametrically opposite corners of the first pair extend parallel to the longitudinal axis.

In a preferred embodiment of the absorbent core, the diamond shaped pockets are square and range from about 1.5 cm x 1.5 cm to 3.0 cm x 3.0 cm.
Another aspect of the invention is an absorbent core for an absorbent undergarment worn by a person. The absorbent core has a longitudinal axis and has a first absorbent section and a second absorbent section. The first absorbent section is formed from a porous material having a first pair of longitudinally extending side edges. The first absorbent section comprises a first layer and a second layer configured to allow movement of liquid. The first layer is disposed on the second layer. Each of the first layer and the second layer is quilted by a fixedly attached fixation line to form a plurality of first pockets therein. The first pocket of the first layer is partially filled with a slow acting but high absorption capacity of free SAP. The first pocket of the second layer is installed between the outer first pocket and the outer first pocket that are installed in close contact with each of the pair of longitudinally extending side edges. An inner first pocket is included. Each of the outer first pockets is partially filled with a slow acting but high absorption capacity of free SAP. Each of the inner first pockets is partially filled with slow acting but high absorption capacity of free SAP, and the volume of SAP in the outer pocket is equal to that of the SAP in the inner first pocket. Greater than volume. The first section forms a body-facing side that is placed facing the perineal area of the person. The second absorbent section is located below the first absorbent section. The second absorbent section is in fluid communication with the first section. The second section is formed of a layer of porous material. The layer of the second section is configured to allow movement of liquid and is quilted to form a plurality of second pockets, the second pockets having a high speed action but a low velocity. Partially filled with free SAP of absorption capacity. The core is configured such that fluid excreted by a person flows into the first fast acting SAP and the slow acting SAP, while the fluid is quickly and rapidly absorbed by the fast acting SAP. The slow acting SAP desorbs or removes fluid from the fast acting SAP and absorbs the fluid itself.

In a preferred embodiment of the water absorbent core of the present invention, the first section comprises another layer formed of a porous material configured to allow movement of liquid. The further layer is quilted by a fixedly attached fixation line to form a plurality of first pockets therein, and each of the first pockets of the further layer has a slow action. It is partially filled with high absorption capacity of free SAP.

In a preferred embodiment of the absorbent core of the present invention, the outer first pocket occupies about two-thirds of the width of the first absorbent section.
In a preferred embodiment of the water absorbent core of the present invention, it further comprises a fluid transfer or wicking layer disposed between the first absorbent section and the second absorbent section.

Another aspect of the invention is another absorbent core for an absorbent undergarment worn by a person. The core has a longitudinal axis and has a first absorbent section and a second absorbent section. The first absorbent section is formed from a first layer of porous material and a second layer of porous material. The first layer is configured to allow movement of liquid and is quilted by a fixedly attached fixation line to form a plurality of first pockets in the first layer. The second layer is disposed below the first layer and is configured to allow movement of liquid. The second layer is quilted by fixedly attached fixation lines to form a plurality of first pockets in the second layer. Each of the first pockets of the first and second layers is partially filled with slow acting but high absorption capacity of free SAP. At least some of the first pockets of the second layer are also partially filled with deodorant material. The first layer of the first section forms a body-facing side that is placed facing the perineal area of the person. A second absorbent section is located below the first absorbent section and is in fluid communication with the first section. The second section is formed of a layer of porous material. The layer of the second section is configured to allow movement of liquid and is quilted to form a plurality of second pockets. The second pocket is partially filled with free SAP, which is a fast acting but low absorption capacity. The core is configured such that fluid excreted by a person flows into the first fast acting SAP and the slow acting SAP, while the fluid is quickly and rapidly absorbed by the fast acting SAP. The slow acting SAP desorbs or removes fluid from the fast acting SAP and absorbs the fluid itself.

In a preferred embodiment of the absorbent core of the present invention, the core further comprises a fluid transfer or wicking layer disposed between said first section and said second section.
In a preferred aspect of the absorbent core of the present invention, the first section comprises another layer formed of a porous material configured to allow movement of liquid. The further layer is quilted by a fixedly attached fixation line to form a plurality of first pockets therein. Each of the first pockets of the separate layer is partially filled with slow acting but high absorption capacity of free SAP.

In another aspect of the invention, there is provided a method of making a disposable absorbent undergarment that is configured to be worn by a person. The method comprises providing a body and an absorbent core assembly. The body includes a first sheet of cloth-like non-woven breathable material. The first sheet has an inner surface, a front portion, a back portion, a crotch portion positioned between the front portion and the back portion, and an absorbent core receiving area including the front portion, the back portion and the crotch portion. There is. The front portion includes an upper front edge and a pair of front side edges, and the back portion includes an upper back edge and a pair of back side edges. The crotch portion has a pair of central side edges. Each of the pair of central side sections comprises an ergonomically shaped recess configured to form a respective leg opening for a human. The recesses are spaced from each other by a first distance. A plurality of pre-stretched elastic yarns are fixed to the first sheet. The plurality of pre-stretched elastic yarns are parallel to the upper front edge and the first pre-stretched elastic yarns extending from one of the pair of front side edges to the other of the pair of front side edges, and the upper back edge and A second plurality of pre-stretched elastic yarns extending from one of the pair of back side edges to the other of the pair of back side edges in parallel with each other, and the upper front edge, the upper back edge, and the pair of pre-stretched elastic threads in parallel with each other. A third plurality of pre-stretched elastic yarns extending from one of the center side edges to the other of the pair of center side edges. A plurality of the plurality of pre-stretched elastic yarns are divided into separate sections at the absorbent core receiving area. The absorbent core assembly is configured to absorb fluid from a person and has a width that is less than the first distance. An absorbent core assembly is secured to the inner surface of the body between the absorbent core receiving section and each leg opening. Each of the front side edges is fixed to each of the back side edges.

In a preferred embodiment of the method of making the disposable absorbent underwear of the present invention, the spacing between adjacent elastic threads is in the range of about 4-5 mm.
In another preferred aspect of the method of making a disposable absorbent underwear of the present invention, the plurality of pre-stretched elastic threads of the front portion extend from a point closely adjacent to the upper leading edge to the middle portion. And the plurality of elastic threads of the back portion extend from a point in close contact with the upper back edge to the intermediate portion.

In another preferred aspect of the method of making the disposable absorbent underwear of the present invention, the pre-stretched elastic yarns are tinted to be easily visible from the outer surface of the underwear.
In another preferred aspect of the method of making the disposable absorbent undergarment of the present invention, the undergarment includes a waistband portion adjacent the upper front edge and the upper back edge. The waistband portion includes a plurality of pre-stretched waistband elastic threads extending parallel to the upper front edge and the upper back edge. The pre-stretched waistband elastic yarn has a greater degree of tension or elasticity than the pre-stretched elastic yarn in the portion of the body between the waistband portion and the crotch portion.

In another preferred aspect of the method of making the disposable absorbent underwear of the present invention, the pre-stretched elastic yarn of the portion of the body between the waistband portion and the crotch is directed toward the crotch portion. Exhibit a decreasing tension or stretch gradient.

In another preferred aspect of the method of making the disposable absorbent underwear of the present invention, the tension or stretch gradient comprises at least three zones of different tension or stretch.
In another preferred aspect of the method of making a disposable absorbent undergarment of the present invention, the absorbent core assembly comprises a first section and a second section. The first section is formed from at least one layer of porous material configured to allow movement of liquid. The at least one layer of the porous material of the first section is quilted to form a plurality of first pockets. Each of the first pockets is partially filled with slow acting but high absorption capacity of free SAP. The second section is installed below the first section and has a predetermined width and length. The second section is formed from a layer of porous material configured to allow movement of liquid. The porous material of the second section is quilted to form a plurality of second pockets. Each of the second pockets is partially filled with fast acting but low absorption capacity of free SAP. The first section of the absorbent core assembly and the second section of the absorbent core assembly are in fluid communication with each other, and the second section of the absorbent core assembly is the second section of the absorbent core assembly. It is installed closer to the body than the section.

In another preferred aspect of the method of making a disposable absorbent undergarment of the present invention, the absorbent core assembly further comprises an intermediate wicking layer disposed between the first section and the second section.

In another preferred embodiment of the method of making the disposable absorbent underwear of the present invention, the wicking layer comprises an airlaid material.
In another preferred aspect of the method of making a disposable absorbent undergarment of the present invention, the absorbent core assembly comprises a fluid acquisition layer disposed over the first section of the core.

In another preferred aspect of the method of making the disposable absorbent underwear of the present invention, the body further comprises a second sheet of similar size and shape to the first sheet. The main body applies an adhesive layer to at least one surface of the first and second sheets; disposes the plurality of pre-stretched elastic yarns on the adhesive layer; Combining the first and second sheets to sandwich the plurality of pre-stretched elastic yarns between the first and second sheets.

In another preferred embodiment of the method of making the disposable absorbent underwear of the present invention, the layer of adhesive is applied to the inner surface of the second sheet.
In another preferred embodiment of the method of making the disposable absorbent underwear of the present invention, the second sheet further comprises a liquid impermeable barrier layer.

In another preferred aspect of the method of making the disposable absorbent undergarment of the present invention, the absorbent core assembly comprises a first layer of at least one layer of porous material configured to allow movement of liquid. It is done by providing sections. The at least one layer of the first section is quilted by a fixedly attached fixation line to form a plurality of first pockets. Each of said first pockets is partially filled with a first volume of slow acting but high absorption capacity SAP. A second section of at least one layer of porous material configured to allow movement of liquid is provided. The at least one layer of the second section is quilted by a fixedly attached fixation line to form a plurality of second pockets. Each of the second pockets is partially filled with a second volume of fast acting but low absorption capacity SAP. The second volume is different than the first volume. The first section is disposed above the second section so that they are in fluid communication with each other, and the core obtained therein is such that the fluid contacting the first section is the porous of the first section. Flow through the at least one layer of material into the first pocket and from there through the at least one layer of the second section into the second pocket, where the rapid acting SAP rapidly and In contrast to absorbing rapidly, the slow acting SAP desorbs or removes liquid from the fast acting SAP and absorbs the liquid itself.

In another preferred aspect of the method of making the disposable absorbent undergarment of the present invention, the first volume of slow acting but high absorbing capacity SAP is free in the first pocket and is fast acting. The second volume of SAP with low but absorbent capacity is free in the second pocket.

In another preferred aspect of the method of making the disposable absorbent underwear of the present invention, the first section comprises two layers, each of the layers of the first section having the slow acting but high absorption. A plurality of said first pockets containing a portion of the volume SAP.

In another preferred embodiment of the method of making the disposable absorbent underwear of the present invention, said pocket is formed by ultrasonic bonding or thermal bonding or adhesive bonding.
In another preferred aspect of the method of making the disposable absorbent undergarment of the present invention, a wicking layer disposed between the first and second sections is provided to enhance liquid transfer between the first and second sections. It further includes providing.

In another preferred aspect of the method of making the disposable absorbent undergarment of the present invention, it further comprises providing a fluid acquisition layer disposed over said first section.
Another preferred aspect of the method of making the disposable absorbent undergarment of the present invention provides a method of making the absorbent core assembly. The method includes providing a first continuous web of porous material configured to allow movement of liquid. A second continuous web of porous material configured to allow movement of liquid is provided. A high absorption capacity of SAP is applied to the surface of the first continuous web by slow action. The first and second webs are securely bonded together to form a first quilt web. The first quilted web comprises a plurality of pockets each partially filled with the free volume of the slow acting, high absorption capacity SAP. A third continuous web of porous material configured to allow liquid movement is provided. A fourth continuous web of porous material configured to allow movement of liquid is provided. A high absorption capacity of SAP is applied to the surface of the third continuous web by slow action. The third and fourth webs are firmly bonded together to form a second quilt web. The second quilt web comprises a plurality of pockets each partially filled with a free volume of the slow acting, high absorption capacity. The first quilt web is disposed over the second quilt web to form a first section of the absorbent core assembly. The first section has a peripheral edge. A fifth continuous web of porous material configured to allow movement of liquid is provided. A sixth continuous web of porous material configured to allow movement of liquid is provided. A low absorption capacity SAP is applied to the surface of the fifth continuous web at high speed. The fifth and sixth webs are firmly bonded together to form a third quilt web. The third quilt web comprises a plurality of pockets each partially filled with the free volume of the fast acting, low absorption capacity SAP. The third quilt layer forms the second section of the absorbent core assembly. The second section has a peripheral edge. A web of wicking layer is provided below the first section and above the second section. The web of wicking material is sandwiched between the first and second sections. The perimeter of the first section is sealed against the perimeter of the second section to form a composite web. The composite web is a precursor for making a plurality of absorbent core assemblies.

In a preferred aspect of the method of making an absorbent core assembly of the present invention, the plurality of pockets of the first layer and the second layer are offset from each other.
In another preferred aspect of the method of making the absorbent core assembly of the present invention, the bonding of the webs is accomplished by ultrasonic bonding or adhesive bonding.

In a preferred embodiment of the method of making an absorbent core assembly of the present invention, the absorbent core assembly further comprises a fluid acquisition layer formed by a web of fluid acquisition material. The method further comprises disposing a web of the fluid capture material over the first section.

In a preferred embodiment of the method of making the absorbent core assembly of the present invention, the absorbent core assembly further comprises a liquid barrier layer formed by a web of barrier material. The method further comprises disposing a web of the barrier material below the second section.

In a preferred embodiment of the method of making the absorbent core assembly of the present invention, the absorbent core assembly further comprises a liquid barrier layer formed by a web of barrier material. The method further comprises disposing a web of the barrier material below the second section.

In a preferred embodiment of the method of making an absorbent core assembly of the present invention, the absorbent core assembly further comprises a cover layer formed by a web of porous material. The method further comprises disposing the web of porous material over the first section.

In a preferred embodiment of the method of making an absorbent core assembly of the present invention, the absorbent core assembly further comprises rising leg gathers formed by a web of material having a plurality of elastic fibers secured thereto. .. The method further comprises securing the web of material having a plurality of elastic fibers to the cover layer.

In a preferred embodiment of the method of making the absorbent core assembly of the present invention, the composite web is wound onto a reel for subsequent use.
In a preferred embodiment of the method of making the absorbent core assembly of the present invention, liquids from a plurality of disposable absorbent adult incontinence products, infant absorbent underwear, diapers, sanitary napkins, panty liners, or creatures are absorbed. The composite web is provided to a processing production line for making any other absorbent product configured to.

In a preferred embodiment of the method of making the absorbent core assembly of the present invention, a composite web is provided for making a plurality of absorbent undergarments. Each of the undergarments includes a body having a receiving area for the absorbent core assembly. The main body includes first and second sheets. Each of the sheets is of similar size and shape. The body is formed by applying a layer of adhesive to the surface of at least one of the first and second sheets. A plurality of pre-stretched elastic yarns are disposed on the layer of adhesive. The first and second sheets are brought together to sandwich the plurality of pre-stretched elastic yarns between the first and second sheets.

In a preferred embodiment of the method of making an absorbent core assembly of the present invention, further comprising splitting a plurality of the plurality of pre-stretched elastic yarns into separate segments at the location of the absorbent core receiving area. ..

FIG. 1 is an isometric view of one exemplary absorbent undergarment constructed in accordance with the present invention and including an aesthetically thin body and an absorbent core assembly mounted within the body. FIG. 2 is an enlarged top view of the absorbent undergarment of FIG. 1, but showing the unfolded condition of the undergarment just prior to sealing its perimeter to complete the undergarment. It is a figure of the main body shown in FIG. FIG. 3 is an enlarged sectional view taken along line 3-3 of FIG. 2. FIG. 4 is an enlarged sectional view taken along line 4-4 of FIG. 2. FIG. 5 is an enlarged sectional view taken along line 5-5 of FIG. 2. 3 is a top view of one exemplary absorbent core assembly of the undergarment shown in FIGS. 1 and 2. FIG. FIG. 7 is a top view of a multi-pocket structure containing slow acting but highly absorbent SAP particles in its pocket, which structure forms one layer of the upper section of the core assembly shown in FIG. 6. FIG. 7 is a top view of a second multi-pocket structure containing slow acting but superabsorbent SAP particles in its pocket, which structure forms the second layer of the upper section of the core assembly shown in FIG. 6. FIG. 7 is a top view of a fluid transfer or wicking layer forming an intermediate layer of the core assembly shown in FIG. 6. FIG. 7 is a top view of one multi-pocket structure containing fast acting but low absorbency SAP particles in its pocket, which structure forms one layer of the lower section of the core assembly shown in FIG. 6. FIG. 11 is a non-scaled, greatly enlarged cross-sectional view taken along line 11-11 of FIG. 6. 3 is a top view of the exemplary alternative absorbent core assembly of the undergarment shown in FIGS. 1 and 2. FIG. FIG. 13 is a top view of a multi-pocket structure containing slow acting but highly absorbent SAP particles in its pocket, which structure forms one layer of the upper section of the core assembly shown in FIG. 12. FIG. 13 is a top view of a second multi-pocket structure containing slow acting but superabsorbent SAP particles in its pocket, which structure forms the second layer of the upper section of the core assembly shown in FIG. 12. FIG. 13 is a top view of a fluid transfer or wicking layer forming an intermediate layer of the core assembly shown in FIG. 12. FIG. 13 is a top view of one multi-pocket structure containing fast acting but low absorbency SAP particles in its pocket, which structure forms one layer of the lower section of the core assembly shown in FIG. 12. FIG. 17 is a cross-sectional view taken substantially along the line 17-17 of FIG. 12, not to scale and greatly enlarged. FIG. 18 is an enlarged cross-sectional view similar to that of FIG. 17, but showing yet another alternative exemplary embodiment of a core assembly constructed in accordance with the present invention. FIG. 8 is a top view similar to FIG. 7, but showing an alternative multi-pocket structure containing slow acting but highly absorbent SAP particles in its pocket, the structure of a core assembly constructed in accordance with the present invention. Form a layer of the upper section of yet another alternative embodiment. FIG. 4 is a block diagram illustrating one exemplary method of the present invention for forming absorbent disposable underwear (eg, adult pants). FIG. 9 is a block diagram of exemplary steps for forming the top or first section of an absorbent core assembly for use in absorbent disposable pants or other absorbent products. FIG. 6 is a block diagram of exemplary steps for forming a bottom or second section of an absorbent core assembly for use with absorbent disposable pants or other absorbent products. FIG. 6 is a block diagram of exemplary steps for forming (eg, assembling) an absorbent core assembly for use in absorbent disposable underwear or pants or other absorbent products. FIG. 6 is a block diagram of exemplary steps for forming (eg, assembling) the body of an absorbent disposable undergarment or pant. FIG. 6 is a block diagram of exemplary steps for forming (eg, assembling) an absorbent disposable undergarment or pant from an absorbent core assembly and body. FIG. 2 is an example side elevation view of a portion of a continuous processing system for performing an exemplary method of making the absorbent disposable underwear or pants shown in FIG. 1. FIG. 2 is an example top view of a portion of an alternative continuous processing system for producing an alternative absorbent core assembly suitable for use as part of the absorbent disposable underwear or pants shown in FIG. 1. 28 is an enlarged cross-sectional view taken along line 28-28 of FIG. 27, showing the creation of the alternative absorbent core of FIG. 27.

Here, like reference numerals refer to the various views of the drawings that refer to like parts and in FIG. 1 there is shown one exemplary embodiment of a disposable absorbent undergarment constructed in accordance with the present invention. The exemplary underwear shown is in the form of pants that are configured for a person (eg, an adult) to wear under clothing, which is comfortable to wear, easy to put on and take off, and is worn under clothing. It provides excellent fluid absorption and other capabilities in extremely thin and aesthetically pleasing structures that are sometimes nearly unnoticed. The pant includes a body 22 and an absorbent core assembly 24, each of which will be described in detail below. However, prior to that, although the exemplary undergarment of FIG. 1 is shown and described in the form of adult pants, many of the features described below are provided so that it may be used with underwear other than pants. It should be pointed out that it can be easily changed using. Furthermore, the core can be used in disposable absorbent products for children and babies, for example the core can be used in the body of a diaper. In fact, with appropriate modification, the core can be configured for use with a body suitable for use with pets. In addition, and most importantly, many of the various components of disposable absorbent articles, either alone or in combination with each other, are novel and include various other types of absorbent products, such as feminine hygiene pads. It has a remarkable effect on panty liners, bandages, etc. Furthermore, the undergarment may include one or more of a deodorant system, a treatment system and a wetness detection system. Any one or more of a deodorant system, a treatment system and a wetness detection system may be incorporated into the absorbent core assembly 24 or installed in the body 22.

The body 22 is best seen in FIGS. 1-5 and basically comprises an outer sheet or shell 26 and an inner sheet or shell 28. The outer sheet is made of a cloth-like breathable non-woven fabric, such as spun melt polypropylene, or spun melt polyethylene, or spun melt polyester. If desired, the outer sheet may be laminated to a barrier film-like material such as a 13 to 28 micrometer (0.5 to 1.1 mil) polypropylene or polyethylene film. The film should be liquid impermeable, such as extrusion coated SMS or the like, to prevent leakage. The inner sheet 28 forms the "body side" sheet of the body and is also made of a breathable nonwoven material, such as spunmelt polypropylene or spunmelt polyethylene, or spunmelt polyester, or the like. The inner and outer sheets are similarly sized and shaped, with the inner sheet disposed over the outer sheet, for example, the Henkel 901B structural adhesive commonly used in the manufacture of disposable absorbent products for adults and infants. Alternatively, it is adhesively secured to it by an intervening layer of adhesive 30 such as a similar structural adhesive to form the body as best seen in FIG. A large number (eg, about 118) of elastic filaments, fibers or threads 32, the details of which will be described later, are secured within the adhesive layer 30 except for the portion of the body that forms the crotch of the undergarment, It extends laterally over the entire width of the body 22. The elastic threads extend parallel to the horizontal axis TX and are closely spaced from each other (eg, about 4-5 mm apart). The elastic threads 32 are typically in a relaxed or unstretched state when the undergarment is not worn. When worn, the elastic thread stretches to conform the undergarment to the wearer's anatomy.

The body includes a front or "belly" section 34, a back or "back" section 36, and an intermediate or crotch portion 38. The crotch portion 38 is centered on the horizontal axis TX.
A recess 40 is installed on the right side edge of the body. A similarly shaped recess 42 is located on the left edge of the body. Both recesses form each leg opening 44 (FIG. 1) of the undergarment. The right recess includes a portion positioned at the front portion, a portion positioned at the crotch portion, and a portion positioned at the rear portion. Similarly, the left recess includes a portion positioned at the front portion, a portion positioned at the crotch portion, and a portion positioned at the rear portion. The front portion 34 includes an upper front edge 46, a right front side edge 48, a portion 50 of the right recess 40, an upper left front edge 52, and a portion of the left recess 42. The upper leading edge 46, like the right front and left front edges 48 and 52, respectively, is linear. The rear portion 36 includes an upper rear edge 56, a right rear edge 58, a portion 60 of the right recess 40, a left rear edge 62, and a portion 64 of the left recess 42. The upper trailing edge 56, like the right and left trailing edges 58 and 62, respectively, is linear.

As is conventional, the portion of the body 22 adjacent the front edges 48 and 52 forms what is commonly referred to as the front "ears" of the body, whereas the portion of the body adjacent the rear edges 58 and 62. Form the ears on the back of the body. Each front ear of the body is secured to each back ear of the body along sealing line 66 by any suitable means, such as ultrasonic bonding, thermal bonding, adhesive bonding, etc. Form the underwear shown.

The front portion 34 need not cover the wearer's body as much as the rear portion 36, that is, the rear portion must cover the wearer's buttocks, while the front portion covers the wearer's abdomen and genital area. Therefore, the distance between the upper front edge 46 and the central portion of the crotch portion defined by the horizontal axis TX is smaller than the distance between the upper rear edge 56 and the central portion of the crotch portion.

The elastic fibers or threads 32 of the front part 34 fall parallel to each other and parallel to the transverse axis TX from the upper leading edge 46 to the front part and adjoin the transverse axis TX, for example about 60 mm from the transverse axis TX. It extends to the point of the section. The elastic fibers or threads 32 of the rear part 36 are parallel to one another and parallel to the transverse axis TX, descend from the upper trailing edge 56 to the rear part and adjoin the transverse axis TX, for example at the crotch part about 60 mm from the transverse axis TX. It extends to the point. The top six or eight elastic threads 32 of the front and back sections form what may be referred to as the "waistband" 12 of the undergarment 10. The elastic threads of the waistband 12 can be the same gauge as the elastic threads that make up the rest of the body, but the elastic threads that form the waistband are heavier to provide a tighter fit at the waistband. It is preferably a gauge. For example, the waistband portion may contain 6 to 8 lycra elastic yarns of 800 decitex (DTEX), while the rest of the elastic yarns of the body are 470 to 680 DTEX lycra. In the preferred embodiment shown, the spacing between all of the elastic threads is constant (eg, 4-5 mm), but the spacing can be separate. In this regard, it is contemplated that the elastic threads of the body can be constructed in a graduated spacing arrangement, and it is desirable to have a very close fit at the waist so that the fibers at the top of the front and back sections can be However, they are spaced closer together than the fibers adjacent to the transverse centerline (axis TX), providing the wearer with a better fit. In this way, the distance from the waistband to the horizontal axis TX can be gradually widened. Alternatively, a constant spacing between the elastic threads could be utilized, but the gauge of the elastic threads could be reduced or stretchability decreased from the waistband to the lateral centerline.

FIG. 2A is an illustration of the body shown in FIG. 2 with elastic threads 32 arranged in a tension or stretch reduction zone from waistband 12 to the point of the body where the threads are free. In the example diagram of FIG. 2A, there are three such zones. The first or upper zone is the area of the body that makes up the waistband 12. The second or middle zone 14 is the area of the body from the waistband 12 to the middle point 16. The third or lower zone 18 is the area of the body from the midpoint 16 to the point where the elastic thread 32 ends. The elastic threads 32 of the waistband 12 may exhibit a stretch or tension level of 250-300 percent. The threads in the central zone 14 may exhibit a stretch or tension of 175 to 250 percent and the threads in the lower zone 18 may exhibit a stretch or tension of 125 to 175 percent. It should be pointed out that these ranges are merely exemplary and that other ranges may be implemented. In fact, instead of three separate zones of reduced stretch, the elastic yarn can be configured so that it exhibits a continuous decrease in stretch from the waistband 12 to the point where the elastic yarn ends.

Irrespective of the gauge and/or spacing and/or stretchability of the elastic threads, it is preferred that the threads be tinted so that they are visible through the nonwoven outer sheet 26. The color can be used to represent the intended user of the undergarment. For example, blue elastic threads may be utilized for men's underwear. Lavender colored elastic threads may be utilized for women's underwear. Green elastic thread may be used for unisex underwear.

Although not required, it is also preferred that the elastic threads that make up either the front or back waistband are uncolored, i.e. white. By doing so, the user can easily determine the correct direction to wear the clothes. In the exemplary embodiment, the elastic bands that make up the rear waistband 12 of the undergarment are uncolored, i.e., white.

Due to the very large number of elastic threads in the front and back sections and the close spacing between them, the body 22 of the present invention has a much smaller number than prior art underwear that uses a much smaller number of more widely spaced elastic threads. Also appears much flatter with less folds. Not only does this give the garment a more aesthetically pleasing appearance, but it also makes the garment very concealable when worn, for example, resembling regular cloth underwear.

As mentioned above, the undergarment includes respective leg openings or leg openings 44 for receiving the wearer's legs when the undergarment is worn. The leg openings or leg openings 44 are stretchable to engage the wearer's legs and form a general leak tight interface with the legs. In particular, one preferred embodiment of the present invention utilizes three elastic fibers or threads 68 to form the leg openings in the front portion 34 of the body and three elastic fibers or threads 68 in the rear portion 36 of the body. The elastic fibers or threads 70 of the book are utilized. The elastic threads 68 and 70 that make up the leg openings are preferably larger gauge than the elastic fibers or threads 32. For example, in one preferred embodiment, elastic fibers 68 and 70 are 800 DTEX lycra. The three elastic fibers 68, which make up the right leg opening 44 part of the front part 34 of the body, extend from the linear side edge 48 to the transverse axis TX along and along the periphery of the right cutout recess 40 of the body. Extend substantially parallel to. From that point, the leg opening fibers 68 extend across the body to the concave arc section 72 where they extend along the perimeter of the left cutout recess 42 on the front of the body up to the linear left edge 52. And extends upward substantially parallel to the peripheral edge. Therefore, the three leg opening fibers 68 are arranged in a substantially V-shaped configuration. Similarly, elastic fibers 70, which make up the right leg opening of the rear portion 36 of the body, extend from the linear rear edge 58 to the transverse axis TX along the perimeter of the cutout recess 40 and substantially parallel to the perimeter. ing. From that point, the leg opening fiber 70 extends across the body into a concave arc section 74 where the leg opening fiber 70 extends to the linear left edge 62, along the perimeter of the rear left cutout recess 43, and the It extends downward substantially parallel to the periphery. Therefore, the three leg opening fibers 70 forming the leg opening portion of the rear portion 36 of the main body are arranged in a substantially V-shaped configuration although they are slightly different in shape from the leg opening fibers of the front portion of the main body.

The arcuate sections 72 and 74 of the elastic fibers 68 and 70, respectively, intersect to form a football-shaped configuration extending about the transverse axis TX. When the body is assembled to the undergarment illustrated in Figure 1, this creates a slightly recessed or bowl-shaped pocket at the transverse axis. The recessed pockets provide a better, more aesthetically pleasing and comfortable fit while improving the concealment of the undergarment when worn under outer garments. In the illustrated exemplary embodiment, the portions of the elastic leg mouth fibers 68 and 70 forming the arcuate sections 72 and 74 are not continuous, but rather there are gaps in the fibers, as illustrated in FIGS. 2 and 5. It should be noted that they are classified as follows. Doing so reduces the tendency of the garment to wrinkle in the crotch region where the portion of core assembly 24 is located, while still allowing that portion of the body to form a bowl-shaped pocket.

Details of the absorbent core assembly 24 are described below. At this time, the absorbent core assembly 24 is generally thin and elongated, such as a rectangular body (eg, about 16 to 22 inches in length, depending on the size of the body used, Suffice it to say that the width is about 12.7 cm (5 inches). The absorbent core assembly is secured between the body inner sheet 28 and the core assembly cover sheet 76 (FIGS. 4 and 5). The core assembly cover sheet 76 is located closest to the wearer's body and is made from a non-woven material such as the outer or inner sheets 26 and 28, respectively, and has a greater length and width than the core assembly 24. The long side peripheral edge 77 of the cover sheet 76 is folded back to form an end flap 79 (FIG. 2). A plurality (e.g., three) of longitudinally extending elastic threads or fibers 82 are disposed between each end flap 79 and the underlying portion of cover sheet 76 immediately adjacent thereto. Further, the portion of the end flap 79 adjacent to each end of the cover sheet 76 is adhesively fixed to the outer surface of the lower layer portion of the cover sheet, and the elastic thread 82 is adhesively fixed in the folded back end flap 77. Thus, the elastic threads 82 extend parallel to each other and parallel to the folded edge of the end flap 79. The end flaps and elastic threads 82 are adhesively secured in place using the same adhesive used to secure the inner and outer sheets 26 and 28 together, respectively. The middle portion of the end flap, i.e., the portion of the end flap between the ends of the coversheet 76, is not adhesively secured to the outer surface of the coversheet to form a rising leg barrier or gather 106, as described below. The underside of the cover sheet 76 is adhesively secured to the inner sheet 28 of the body 22 about its outer edge with an adhesive, for example, the same adhesive used to secure the inner and outer sheets 26 and 28 together, respectively. To do.

As can be seen in FIGS. 4 and 5, a liquid impermeable barrier sheet 78 is interposed and fixed between the core assembly 24 of the main body and the inner sheet 28. Barrier sheet 78 may be made from a film of any suitable material, such as polypropylene, polyethylene, or polyester. The barrier sheet 78, which is liquid impermeable, prevents liquid in the core assembly from leaking out of the core through the body or wet the body.

As best seen in FIG. 2, the core assembly 24 is centered about the longitudinal center axis LX but not the transverse axis TX. One end of the core assembly is located at the front portion 34 of the body, the central portion of the core is located at the crotch portion 38, and the other end of the core is located at the rear portion 36. In particular, one end of the core is located at, or directly below, the left and right side edges 48 and 52 of the front, respectively. The other end of the core assembly is positioned at or directly below the left and right side edges 58 and 62 of the rear portion 36, respectively, wherein a core positioned at the rear of the body is positioned more than a core positioned at the front of the body. Many.

As clearly shown in FIGS. 1, 2 and 4, the portion of the elastic thread 32 located in the area of the body in which the portion of the absorbent core assembly 24 is located is discontinuous or delimited. That is, each elastic yarn is divided into separate segments such that there is a gap 80 between the segments immediately adjacent to each other. As such, the elastic thread segments are not prone to collapsing or buckling the core assembly, thereby contributing to the hiding, aesthetics and comfort of the undergarment. What can be termed the "butt" region of the body that fits the wearer's buttocks when the undergarment is worn, because the portion of the elastic filaments located outside the boundaries of the back core assembly is not discontinuous. To form.

According to one preferred embodiment of the present invention, and as clearly shown in FIGS. 1 and 2, the elastic thread 32 installed in the core assembly is cut or delimited to a 45 degree bias, Create a gap 80. The bias cut has the effect of producing a slightly better looking pattern of interrupted yarn segments than if the elastic yarn 32 were cut parallel to the central longitudinal axis LX. This is because any misalignment in the longitudinally cut segments can be easily perceived, and such misalignment of segments gives the appearance of a random product.

As previously mentioned, in addition to the elastic leg openings 68 and 70 installed in the leg openings 44, the undergarment 10 includes a pair of elastic, erect upright leg barriers or gathers 106. The leg barrier or gather is conventional in that it extends upward from the undergarment at the top of the core assembly to form a fence along either side of the core assembly. Thus, even if there is a very rapid insult (urine release), rather than letting the release flow towards the leg openings, the upright wall directs that invasion into the core. Thus, the leg barrier or gather 106, in conjunction with the elastic leg openings 68 and 70, prevents leakage of invasion from the leg openings 44. The leg barrier or gather 106 is formed by two sets of three elastic threads or fibers 82 (FIG. 2) that are adhesively secured to the core assembly coversheet 76 that closely adjoins its side edges 77. Each of the elastic fibers 82 extends along the entire length of the cover sheet 76. The tension exerted by the fiber or thread tends to cause the middle portion of the core assembly coversheet 76 to rise from the core assembly when the garment is in the condition as shown in FIG. 1, that is, when ready to be worn. Hold.

6-11, the details of core assembly 24 will now be described. The core assembly is designed to absorb liquids that emerge or are expelled from the adult body in some way. The core assembly 24 has particular utility for use as a component of underwear (eg, protective disposable pants), but may be used in other applications.

The absorbent core assembly 24 is a generally flat body having any suitable perimeter shape. In this exemplary case, core assembly 24 is an elongated rectangle. It has a longitudinal axis parallel to the longitudinal axis LX and a lateral axis parallel to the lateral axis TX. An exemplary embodiment of a core assembly is clearly shown in FIGS. 4, 5 and 11 and basically comprises a first or upper absorbent section 84, a fluid transfer or wicking layer 86, a second or Bottom absorbent section 88. Preferably, but not necessarily, a fluid acquisition layer 85 similar to that of prior art absorbent undergarments is placed between the core assembly coversheet 76 and the first absorbent section 84. The trapping layer 85 serves to cause the liquid to be absorbed to flow linearly across its area and spread throughout the core assembly. One exemplary embodiment of a fluid acquisition layer that can be used in the present invention is a 12.1 cm wide through air bonded ADL40 GSM (grams per square meter: grams per square meter). Other materials can also be used for the fluid acquisition layer. For example, Shalag ST6CT8H50, STAPPEL40ADL, STA1PBL40 or STA2PBL38m, sold by Shalag US, Inc. (Shalag US, Inc.), or similar suppliers produced by WPT Corporation or other similar ADL nonwoven materials. It is a material. Such a material is specified by the vendor as GSM basis weight 100% polyester white. Other similar airlaid acquisition layer materials incorporating polypropylene, polyethylene composite fibers or the like used in the industry can also be used, with uses as low as 20 GSM or rarely up to 100 GSM, Ideally, the basis weight is 40 GSM±10 GSM. Another alternative is to use a 3D film, such as that available from Tredegar Film Products under the trademark AquiDry Plus 120. In any case, the fluid acquisition layer is preferably coextensive in size and shape with the first absorbent section 84.

The first or upper absorbent section 84 is in the shape of an elongated rectangle, is provided for the linear flow of liquid, and is in the form of at least one, preferably two or more quilt layers. In the preferred embodiment shown herein, the first absorbent section 84 is made up of two quilt layers, a first layer 90 and a second layer 92 (shown in Figures 7 and 8, respectively). .. Each of these layers is in the form of a pair of non-woven sheets, which are secured together along intersecting sealing or embossing lines 94 to provide a plurality of diamond-shaped features between intersecting embossing lines. To form a closed pocket 96. The first layer 90 of the first absorbent section 84 is in the shape of the plurality of first pockets 96 and the second layer 92 is in the shape of the plurality of first pockets 96. The sealing line 94 can be formed by any appropriate method, for example, ultrasonic welding, heat welding, adhesive fixing, or the like.

Each first pocket 96 has, for example, a square shape of about 1.5 cm×1.5 cm, and the width of each intersecting sealing line is about 1 mm. If desired, the first pocket can be of a larger size (eg, 3.0 cm x 3.0 cm, or larger).

The first pocket 96 is oriented such that two of its diametrically opposite corners extend parallel to the longitudinal axis of the core assembly 24, while the other two diametrically opposite corners extend transversely or orthogonally to that axis. Each pocket is partially filled with free SAP, as described below. As will be appreciated by those in the art, the orientation of the pocket with respect to the longitudinal axis establishes a tortuous flow path for the fluid along the longitudinal axis of the core. Furthermore, the quilted nature of the two layers 90 and 92 of the first section 84 causes the loose SAP particles of the layers of that section to resist migration with respect to the core assembly, thus binding the adhesive to the SAP particles and causing the particles to bind. Eliminates the need to prevent the movement of

The non-woven sheet making up the two layers of the first absorbent section may be a liquid permeable non-woven material, such as a hydrophilic spunbond non-woven polypropylene of 12.1 cm width and 15±5 GSM basis weight or the like. it can. One particularly suitable non-woven fabric is available from PGI Nonwovens under the code number B0305 white SBPP hydrophilic polypropylene spunbond. At a minimum, the upper bodyside layer is hydrophilic and the bottom layer may be similar for ease of manufacture. Alternatively, it could be a hydrophobic or barrier film.

Each of the first pockets 96 of layers 90 and 92 of the first absorbent section 84 contains a high capacity but slow absorbed free SAP 98, each first pocket being the pocket illustrated in FIGS. 7 and 8. Less than half its volume or volume, preferably within about 25 to 35 percent of its volume or volume, as indicated by the dashed line. In particular, according to one preferred aspect of the present invention, the amount or volume of SAP 98 in at least a portion of the first pockets 96 of the first layer 90 is within the range of about 25 to 35 percent of the volume or volume of the first pockets. Is. Further, the amount or volume of SAP98 in at least a portion of the first pocket 96 of the second layer is within the range of about 80 to 120 percent of the amount or volume of SAP98 in the first pocket of the first layer, and the second layer Within 25 to 35 percent of the volume or capacity of the first pocket of the. To that end, each pocket 96 encloses about 0.02 to 0.05 grams of SAP, or about 100 to 196 grams of SAP per square meter.

Partially filling the pocket with a high capacity but slow absorbing SAP98 helps to allow the SAP to swell and swell when in contact with the liquid to be absorbed (eg urine). If pockets 96 were loaded with significantly more SAP98, such as more than 0.10 grams per pocket, the SAP would have limited ability to swell and therefore be unable to absorb additional fluid. In some cases it may be appropriate to employ 0.03 grams or even 0.02 grams to underfill the pocket to reduce capacity and ensure maximum utilization. It should also be pointed out that other size pockets than those described above are contemplated. For example, larger pockets can be employed to increase the amount of SAP98 per pocket. In any case, the ratio of SAP to pocket size should preferably not exceed about 0.44 grams per square cm per pocket. If larger pockets are contemplated, the same weight per unit area ratio should be applied.

In any case, the high capacity but slow absorption SAP98 has a relatively high vortex time, for example, about 30 to 90 seconds or more, and as described later, the whole liquid excreted by the user is cored. It is preferable to ensure absorption at that section of the assembly. According to one exemplary embodiment of the invention, SAP 98 can be BASF T-9900 available from BASF Corporation, or other suitable SAP.

If desired, the two layers 90 and 92 of the first absorbent section 84 can have one or two layers of non-woven fabric interposed between the layers 90 and 92. The use of such a layer, a layer of non-woven material interposed between layers 90 and 92, should help to provide more pockets and layers with more void space to allow faster fluid flow. ..

The fluid transfer or wicking layer 86, best seen in FIG. 9, serves to assist the transport of excreted fluid by wicking or the like. In particular, the layer 86 helps to draw the fluid linearly along the longitudinal axis, so that the liquid to be absorbed (eg, urine) is removed from the central central area of the core where the liquid is first invaded. Are configured to flow to an end that may not fully reach and allow the liquid to enter the second absorbent section 88 through the layer 86. In an exemplary embodiment, the wicking layer is about 100 GSM airlaid tissue. One particularly suitable material for the wicking layer is available from Domtar/EAM Corporation under the Nova Thin trademark and is described as a 100 GSM basis weight white fiber web. The wicking layer has a corduroy or corrugated embossing pattern employed to further aid wicking. The corrugated or corduroy pattern is formed by a plurality of closely spaced parallel sealing lines 104 made by any suitable technique, such as ultrasonic welding, heat welding, adhesive fixing, and the like. The wicking layer is also in the shape of an elongated square, but is preferably narrower than each of the first and second sections 84 and 88, for example, about 5.1 cm wide, for reasons described below. The wicking layer is not bonded, again for the reasons explained below. Further, the wicking layer may be in the form of multiple layers to provide the desired wicking properties. The wicking layer may also have visible holes of size 5 mm or greater that are added to further improve fluid passage.

The second or bottom absorbent section 88 is preferably coextensive in size and shape with the first or top absorbent section 84 and is configured to be positioned away from the wearer when the undergarment is worn. .. The second absorbent section 88 is structured somewhat like the first absorbent section 84, but in the form of a single quilt layer. The layers are formed in the same manner as each of the layers of the first absorbent section, i.e., made of the same material as the sheets of the first absorbent section and secured together along the intersecting sealing or embossing lines 94. And a pair of non-woven sheets forming a plurality of closed diamond-shaped second pockets 96 between intersecting embossing lines, such as pockets 96 of the first absorbent section 84. The second pocket 96 of the second absorbent section 88 can be the same size as the first pocket of the first absorbent section, eg, 1.5-3.0 square cm, or the first pocket of the first absorbent section 84. It may be of a different size than the pocket, for example smaller than the first pocket, but is still within the range to allow greater expansion of the high fluid absorption capacity of SAP98.

Each of the second pockets 96 of the second absorbent section 88 is partially filled with a fast acting but low absorbent capacity of free SAP 100. In particular, each second pocket is filled to less than half its volume or volume, preferably within about 20-30% of its volume or volume. The vortex time of SAP100, which has a fast acting but low absorption capacity, is much faster than the vortex time of SAP98, which has a slower acting but higher absorption. Thus, for example, SAP 100 may have a vortex time in the range of approximately 3-20 seconds. Furthermore, the ratio of the slow acting SAP98 of the first absorption section to the fast acting SAP100 of the second absorption section should be somewhere in the range of about 6:1 to 3:1, with higher ratios being preferred. preferable. Thus, for example, one suitable vortex time for SAP98 should be at least 60 seconds and the vortex time for fast acting SAP should be 10 seconds or less. According to one exemplary embodiment of the present invention, the fast acting SAP 100 can be Aquakeep type BA40B available from Sumitomo Seika Co., Ltd., or the like. The product has a very fast (eg, about 3 to 10 seconds) vortex time.

Like the first absorbent section, the quilting of the second absorbent section requires an adhesive to bond the SAP of the second absorbent section to the superabsorbent particles to prevent flow or migration of the superabsorbent particles. Without resisting movement with respect to the core assembly.

Each pocket 96 of the second absorbent section 88 encloses about 0.02 to 0.04 grams of SAP, or about 150 GSM. Because the pockets are only partially filled, they allow the superabsorbent polymer to swell and swell when in contact with fluid, similar to the pockets of the first absorbent section 84. If the second section pockets 96 were loaded with significantly more SAP, such as more than 0.06 grams per pocket, the SAP particles would be limited in their swelling capacity and therefore unable to absorb additional fluid. Let's do it. However, other size pockets may be contemplated to increase the amount of SAP per pocket by employing larger pockets. In each case, the ratio of SAP100 to pocket size should preferably not exceed about 0.16 grams per square cm per pocket. If larger pockets are contemplated, the same weight per unit area ratio should be applied.

The fast acting SAP 100 may have some tendency to crumble during the processing and formation of section 88. Therefore, in order to minimize this potential problem, a lubricant such as mineral oil can be added to the SAP100, the mineral oil being in the range of 0.1% to 5%, preferably 0.1 to 1. It is in the range of 0%. Further, during processing and formation of the bottom section 88, water may be added to the SAP 100 of that section to reduce dusting. The result of such operation is that the SAP 100 of the bottom section 88 has a higher water content than the SAP 98 of the top section 84. Furthermore, due to the inherent nature of the bottom section SAP 100, some slower acting SAP 98, such as the first section 84, is added to the second or bottom section fast acting SAP 100 to minimize gel block up to 20%. Can be limited or prevented. Furthermore, if desired, the non-woven material making up the bottom sheet of the quilt second section 88 is to add SMS or non-woven or poly or pigmented specifications to the SAP to show the bottom of the absorbent core assembly from the top. Can be done by coloring or printing on the bottom. This is to eliminate the possibility of inverting the absorbent structure, which would result in a non-functional absorbent core.

The layers 90 and 92 of the first section 84 of the core assembly and the single layer of the second section 88 are secured together along their peripheral (longitudinal) edges by respective sealing lines, And a second section with a wicking layer interposed to form a composite core assembly. These sealing lines can be formed by any appropriate method, for example, ultrasonic welding, heat welding, adhesive fixing, or the like. The most desirable process is to ultrasonically bond the components together, with a 2 mm wide intermittent bonding pattern extending on both sides of the composite core assembly, spaced approximately 1 cm from each edge, eg, per cm. Approximately four connecting points or bars, making it look a bit like a railroad track. The narrower wicking layer 86 than the first and second sections helps bond the components of the core assembly together. Moreover, being narrower, the wicking layer 86 can allow fluids excreted by the person wearing the undergarment 10 to overflow beyond the side edges and into the underlying second absorbent section. , Facilitates fluid transfer to that section.

When the undergarment is worn with the absorbent core assembly 24 installed in the undergarment, the absorbent core assembly forms the body-facing side of the undergarment facing the wearer's perineal region. Therefore, when the wearer excretes, the urine flows into the first absorbent section 84 and into the fast acting SAP 98 located in the pocket 96 of the top layer 90 of that section, and from there to the bottom layer 92 of that section. , Pass through that layer. Due to the slow action of the SAP 98 in the upper section 84, excreted urine quickly flows out of the upper section 84 and travels to the lower wicking layer 86 where it is spread over the area of the wicking layer, through which Go over the perimeter to the underlying second absorbent section 88. It is in the second absorbent section that liquid is rapidly and rapidly absorbed by the fast acting SAP 100 located in the pocket of the second absorbent section, while the slow acting SAP desorbs or removes liquid from the fast acting SAP. , Absorbs the liquid itself. The wicking layer 86 also helps improve fluid transfer from the lower, faster absorbent second absorbent section 88 to the higher, slower absorbent first absorbent section 84.

Preferably, the embossing pockets of the first and second absorbent sections are not directly aligned with each other to improve fluid flow through the composite absorbent core assembly. Rather, they are displaced in a direction parallel to the longitudinal axis LX and/or a direction parallel to the transverse axis TX, or in a direction parallel to both the longitudinal axis and the transverse axis. This improves fluid flow not only in the longitudinal and lateral directions, but also in the direction orthogonal to the plane of the core assembly. 12-17 show an alternative embodiment of the core assembly 124 in which the pockets of the first and second sections are offset rather than coincident. For the sake of brevity, the structural details of the components of core assembly 124 that are common to core assembly 24 are labeled with the same reference numerals and their construction and operation will not be repeated.

The core assembly 124 offers several advantages in terms of facilitating fluid flow therethrough, but for the ease and simplicity of manufacture of the core assembly, reduced capital costs and consequent consumer savings. May align the first and second embossed pockets directly below each layer and below each other as in core assembly 24.

As will be appreciated by those skilled in the art, the core assembly quilt structure of the present invention functions by what may be referred to as the "compartment overflow phenomenon." In particular, the liquid that is absorbed as it comes to each section of the core fills the SAP contained in that section's compartment (pocket), where the compartment and the SAP therein swell. When the SAP in that compartment is fully utilized (eg, swelled to its maximum), the liquid also “floods” into the adjacent compartment. As mentioned above, the ultrasonically formed diamond-shaped pockets or compartments 96 of the first and second absorbent sections, respectively, are interspersed between them as a result of the width of the sealing lines 94 which are securely fixed across each other. It has a space of about 1 mm. This aids in the flow of liquid along the voids in the core assembly adjacent its sealing line illustrated in the cross-sectional views of FIGS. 11, 17 and 18. The wicking layer 86 also enhances liquid flow, as well as the unaligned nature of the compartments or pockets. The addition of a top bodyside capture layer 85 further aids in fluid transfer, facilitating fluid spillage from one SAP containing compartment or pocket to the next.

Further, by utilizing the two layers 90 and 92 of the first absorbent section 84, the core assembly 24 allows each of the pockets 96 of the first section to accommodate the case where the first section includes only a single quilt layer. It is possible to use less SAP 98 than is used. Thus, there is less SAP 98 in a given pocket, so there is enough room for the SAP 98 to expand in the pocket so that it is fully available for desorption of SAP from the second absorbent section. .. For economic reasons, it is desirable to use the minimum amount of SAP in the pocket of the first absorbent section, but if the amount used is not sufficiently available to achieve the desired absorption rate and capacity. I won't. Therefore, the SAP 98 of each of the two layers 90 and 92 of the first absorbent section is within the desired range of pocket fill described above, and the time of 30 to 90 seconds is sufficient to allow the SAP to fully desorb liquid from the second absorbent section. It is desirable to have a vortex time in the range of. Moreover, the configuration maximizes the performance of the SAP and does not tend to obstruct the flow of liquid to the second absorbent section by the SAP98 of the first absorbent section, such as may result from "gel blocks", and the Allows efficient and effective transfer of liquid introduced into the core assembly through each of the two layers to the second absorbent section. As is known, "gel block" occurs when the surface of the SAP of a section in contact with a liquid swells first, blocking the lower level of SAP in that section from fully absorbing up to its maximum capacity. To do. By using less SAP in each pocket, but by using more pockets through the two layer structure of the first absorbent section, gel block generation is minimized, if not eliminated. It can be suppressed. Thus, the liquid introduced into the core assembly quickly passes through the first absorbent section and is drawn up to the second absorbent section where it is quickly absorbed by the SAP of the second absorbent section, from which the liquid is All of the liquid is trapped in the core assembly, allowing the wearer to dry, as it can return to one absorbent section and the liquid is slowly absorbed in the first absorbent section, thereby desorbing the second absorbent section Keep in the state.

If a higher capacity absorbent core assembly is desired, additional SAP layers such as those in the first section could be added to the structure. Thus, for higher capacity pants (eg, those suitable for night wear), the first absorbent section may include three quilt layers, each of the three quilt layers having two quilt layers 90 as previously described. And 92 as well. An alternative embodiment of the core assembly is illustrated in FIG. 18 and is designated by the reference numeral 224. The core assembly 224 is similar in construction to the core assembly 124 illustrated in FIG. 17, except that the first absorbent section 184 includes three quilt layers. In particular, the first section 84 includes a first layer 90, a second layer 92 and a third layer 93. For the sake of brevity, structural details of the components of core assembly 224 that are common to core assemblies 24 and 124 are labeled with the same reference numerals and their construction and operation will not be repeated. The third layer 93 is structured similarly to layers 90 and 92 and is also partially filled with slow acting, superabsorbent SAP98, which is at least some of the SAP98 in the first pocket of the third layer 93. The volume or amount is within the range of about 80-120 percent of the volume or amount of SAP98 in the first pocket of the second layer 92 and about 25-35 percent of the volume or volume of the first pocket of the third layer 93. It is within the range.

It should be noted that the core assemblies described so far utilize the same amount of SAP in the pockets of each layer of the first absorbent section. It is merely an example. Thus, for example, the core assembly may have a high density portion at the long side perimeter such that the core assembly has a pocket or zone of slow acting but highly absorbent SAP98 concentration in the layers of the first absorbent section 84. It is contemplated that it may be structured adjacent to. Such a configuration should prevent liquid from leaking to the sides of the core assembly and is illustrated in FIG. In particular, in FIG. 19, the pockets located adjacent the long side edges of the core assembly, shown as 96A and shaded by closely spaced vertical lines, are more Also loaded with a higher concentration or amount of SAP98. The pocket filled with less SAP is designated by reference numeral 96B. Thus, as can be seen, the pocket 96A forms two lines or zones extending along the perimeter of the core assembly. Each muscle of higher concentration SAP98 is preferably about 1/3 of the width of the core assembly. It is merely exemplary, and the lines that make up the higher and lower concentrations of SAP98 can be of different widths.

In either case, if different concentrations of SAP98 muscles or zones are used, the amount of SAP98 in pockets 98A and 96B should still be within the previously mentioned range. Also, when structuring the core assembly like the core assembly of FIG. 17, the layer utilizing different concentrations of SAP98 stripes or zones is preferably the second layer 92. When a core assembly utilizing different concentrations of SAP98 muscle or zone layers is structured as in the embodiment of FIG. It may be one or both of 93, but is preferably the second layer 92. In either case, the first or upper layer 90 should be kept as dry as possible because it faces the body, so it is preferred that the layer 90 does not contain muscle or zones with high or low concentrations of SAP98.

As will be appreciated by one of ordinary skill in the art, using layers of different concentrations of SAP98 in the first absorbent section may result in liquid attack (eg, drainage) because SAP98 in the first absorbent section does not absorb liquid quickly. Urine) should not be prevented from being rapidly transferred from the first absorption section to the second absorption section.

It is also contemplated in the present invention that inexpensive inorganic additives can be used to maximize the performance of the SAP. The purpose of the assembly core of the present invention is to allow all the SAP particles in each section to achieve their maximum absorption capacity, so that they do not swell or increase the gel blocking phenomenon, high porosity zeolites, upsalites, microspheres or Inorganic additives such as other inorganic materials may be included with the SAP of the core. Another approach, which is an alternative to the use of such inorganic additives, or an additional approach to the use of such additives, is to utilize a trapping layer such as 40 gm Shalag ADL from Shalag US Inc. , Or similar material available from WPT Corporation or others may be placed under the second absorbent section of the core. In addition, if desired, a second wicking layer could be added between the first and second absorbent layers.

Moreover, the fast acting SAP100 of the second absorption section has a very fast vortex time, so that in some cases, especially in the body surface of the SAP particles in the pocket rather than the particles of SAP100 installed inside the body of the SAP. The SAP 100 particles that are placed closest to them may have a tendency to gel block. In such cases, the internal particles of SAP100 may not have the opportunity to absorb the fluid insult. To address this issue, a "caking inhibitor" or "fluidizer" may be added to the pocket containing the high speed SAP 100 and blended with the SAP in that pocket. The caking inhibitor or superplasticizer can take the form of calcium sulfate, magnesium carbonate, diatomaceous earth, kaolin, calcium silicate, or the like. Hollow glass or plastic microspheres, such as those manufactured by 3M, could also act as an inert fluidizer. In any case, the caking inhibitor or superplasticizer may occupy 5-20% of the volume of SAP100 in the pocket and should preferably have a particle size similar to or larger than the particles of SAP100. .. In this regard, SAP 100 has a micrometric distribution of less than 11% less than 250 microns, about 73% between 250 and 500 micrometers, and about 16% greater than 500 micrometers, and 850 micrometers. There is no bigger one. As such, it is contemplated that the anti-caking agent will have a particle size greater than 250 micrometers, but perhaps less than 850 micrometers.

Enzymes such as zeolites, EDTA, amylases, lipases, proteases or the like, and commercially available products such as FEBREZE® deodorants, ZERO ODOR®, etc. to control or reduce odors , And combinations thereof, as well as some or all of the first pockets 96 of the first absorbent section. Being very porous, zeolites collect odors. However, when it gets wet, its odor absorbing capacity decreases. Because the zeolite odor modifier is located in the pocket 96 where the high volume SAP 98 is located, the SAP can function to desorb water from the zeolite, thereby reducing odor over a long period of time. In order to keep the wearer of underwear 10 dry, it is preferred that no zeolite odor control agent be placed in layer 90. This is because that layer is placed closest to the wearer when the undergarment 10 is worn. Thus, if the first absorbent section of the core assembly comprises two quilt layers 90 and 92, such as that of FIG. 17, then the zeolite odor modifier should be placed in layer 92. If the first absorbent section of the core assembly comprises three quilt layers 90, 92 and 93, such as in FIG. 18, then the zeolite odor modifier is preferably placed in layer 92, but one of layers 92 and 93. Or it should be installed in both.

Absorbent core assemblies structured in accordance with the present invention, such as those described above or variations thereof, could be used in place of the absorbent core employed in currently existing absorbent products. For example, absorbent core assemblies structured in accordance with the present invention may include adult incontinence products (eg, pants, panties, pads, etc.), infant absorbent underwear (eg, diapers), sanitary napkins, feminine napkins, It can be used in a panty liner, or any other product that the creature is configured to wear to absorb liquid from the creature. Further, while the pockets of the two sections 84 and 88 of the core assembly are diamond-shaped and all of the pockets are shown to be the same size, this is merely an example. Thus, it is contemplated that other shaped pockets can be used for either section 90 or 92 or both sections 90 and 92. Examples of other shapes that may work equally well include rectangles, squares, circles, ovals, parallelograms, pentagons, other shapes and sizes, and combinations thereof. Indeed, it is also contemplated that the pockets of the two layers 90 and 92 are of different shapes if desired. Furthermore, the core assembly may be configured to include SAP elevations in each or any of the layers of the core assembly. Also, SAP can have different concentrations of SAP in the muscle). It can be as high as ±25% minimum from high to low, or as high as 75% from high to low. Depending on the amount of fluid flow desired, these streaks can be arranged mountain-to-peak or mountain-to-valley.

As will be appreciated from the above, the core of the invention described above utilizes at least two sections, each of which is a quilt structure including a plurality of pockets. In addition, each of the pockets is hollow and partially filled with SAP. The SAP may be free or unfixed particles or fibers, or any other form of SAP. The pocket serves to hold the SAP in it and prevent it from moving through the core. However, it is contemplated that in some applications the adhesive may also be used in the pocket to hold the SAP in place. The alternative configuration provides an additional means in addition to the pocket to prevent the SAP from moving through the core.

Turning now to Figures 20-27, details of various methods according to the present invention for making the exemplary absorbent underwear and exemplary absorbent core assembly described above will be described.
One (possibly the simplest) method for making an absorbent core assembly is shown in the block diagram of FIG. The method basically comprises forming the upper or first section 84 of the core 24 shown at block 200. The manner of forming that section of the core will be described with reference to FIG. The bottom or second section 88 of the core 24 is formed according to block 202, and the specific manner of forming that section is described with reference to FIG. The assembly of the first section 84 and the second section 88 to form the absorbent core assembly 24 is shown at block 204, the details of which will be described with reference to FIG. A specific method of forming the body 22 of the absorbent underwear or pants 20 according to block 206 and forming the body will be described with reference to FIG. The formation or assembly of the completed undergarment 20 is accomplished by block 208, the details of which will be described with reference to the example diagrams of FIGS. 25 and 26.

Thus, turning now to FIGS. 21-26, a first layer or web of about 15±5 GSM polypropylene spunbond nonwoven material or the like is provided as shown in block 210. As described in block 212, the first layer or web is drawn from a reel 300 of such material and a slow acting but high capacity SAP98 is delivered from the particle feeder 302 to about 100 to 200 grams per square meter. It is applied (eg, sprinkled) onto the web material at a rate of (GSM). Smaller or larger amounts of SAP may be applied as a product design guarantee. A second layer or web of similar nonwoven material is provided as described in block 214. In particular, the second web is unwound from reel 304 and passed over rollers 306 and under another roller 308 so that the second web is on the first web and SAP98 is interposed between the webs. Integrated or combined with. The combination of webs is further passed through an ultrasonic bonder 310, most preferably with a diamond embossing pattern forming a plurality of diamond-shaped pockets 96 in the webs, as described in blocks 216 and 218. , Thereby trapping the free SAP98 in their pocket. The pockets are preferably about 15×15 mm or greater and the width of the ties separating the pockets is about 1 to 3 mm. Other dimensions, sizes and shapes may be used in place of the diamond shaped pockets described above. Also, the edges of the web are ultrasonically sealed/bonded continuously with a bonder 310, as described in block 218, with edges having a width of about 1 to 3 mm, and the SAP98 is swung from the pocket at the edges of the web. Don't get dropped. Although less preferred, it is still acceptable to use hot melt adhesives or the like to bond diamond-shaped pockets and edges or pockets or edges or a combination thereof in this single layer absorbent core assembly structure. Anything can be used. This action completes the top quilt layer 90 of the first section 84 and then passes it over the rollers 312 to secure the continuous web of that section to the bottom quilt layer 92.

The bottom quilt layer 92 of the first section 84 is made of third and fourth webs made of the same material as the top layer 90 and assembled in the same manner as described in blocks 220-228. This results in a plurality of diamond-shaped pockets partially filled with SAP98, similar to that of top layer 90. In particular, a third layer or web is drawn from a reel 314 of such material and a slow acting but high volume SAP98 is applied from the particle feeder 316 onto this web material as described in block 222. (For example, spraying). A fourth layer or web of similar nonwoven material is provided as described in block 224. In particular, the fourth web is withdrawn from another reel 318 and passed over rollers 320 and under another roller 322 so that the fourth web is on the third web and the SAP98 is interposed between the webs. Integrated or combined with. This web combination is passed through a further ultrasonic bonder 324 to form a plurality of diamond-shaped pockets 96 in the web, as described in blocks 226 and 228, thereby releasing free SAP98. Capture in that pocket. The edges of these webs are also ultrasonically sealed/bonded continuously with a bonder 324, as described in block 228, with edges having a width of about 1 to 3 mm and the SAP98 at the edges of the web. Don't get shaken from your pocket. This action completes the bottom quilt layer 92 of the first section 84 and separates the continuous web of that section for later securing to the top quilt layer 90, as will be briefly described below. Pass over roller 326.

The second section 88 of the absorbent core assembly 24 is formed as shown in block 202 of FIG. 22 and as shown in FIG. In particular, a first layer or web of about 15±5 GSM polypropylene spunbond nonwoven material or the like is provided as described in block 230. The first layer or web is drawn from a reel 328 of such material and a high speed but low volume SAP 100 is loaded from another particle feeder 330 to about 15±5 GSM, as described in block 232. Is applied (eg, sprinkled) onto the web material at a rate of. Smaller or larger amounts of SAP may be applied as a product design guarantee. A second layer or web of similar nonwoven material is provided as described in block 234. In particular, the second web is drawn from another reel 332 of such material and passed over another roller 334 and below another roller 336 so that the second web becomes the first web, It is integrated or combined with the SAP 100 that is interposed between the webs. In particular, as shown in blocks 236 and 238, this combination is passed through another ultrasonic bonder 340, most preferably with a diamond embossing pattern forming a plurality of diamond-shaped pockets 96, the pockets comprising: With a width of about 15×15 mm or more, the width of the connection separating the pockets is about 1 to 3 mm. Other dimensions, sizes and shapes may be used in place of the diamond shaped pockets described above. Also, the edges of the web are ultrasonically sealed/bonded continuously, as shown in block 238, with edges having a width of approximately 1 to 3 mm to prevent SAP 100 from being swung from the pocket at the edges of the web. To Although less preferred, it is still acceptable to use hot melt adhesives or the like to bond diamond-shaped pockets and edges or pockets or edges or a combination thereof in this single layer absorbent core assembly structure. Would use the This action completes the quilt layer of the second section 88.

The first section 84 and the second section 88 are assembled to form the absorbent core assembly 24 as described in block 204 of FIG. 23 and FIG. To that end, a fluid transfer web or wicking layer 86 (eg, about 100 GSM corrugated airlaid tissue) is provided, as described in block 240. In particular, web 86 is unwound from reel 342 and passed over roller 344 and under another roller 346, where web 86 is placed over the quilt layer forming second section 88. The bottom layer 92 of the first section 84 is threaded under the roller 348 and the top layer 94 of the first section 84 is threaded under the roller 350 so that it is placed over the bottom layer 92 and further the wicking layer. 86 and an underlying second section 88. Therefore, the first section 84 is disposed over the wicking layer 86, as described in block 242. The three sections/layers are preferably ultrasonically bonded together, as described in block 244. In particular, they are joined together in a tack intermittent bond by another ultrasonic bonder 352, thus ensuring that there is no barrier that prevents maximum absorption of body fluids. Other less desirable alternatives for bonding these layers together are continuous, rather than intermittent, ultrasonic bonding, or spraying, slots, melt blow spray adhesives, stitch bonds, needle felt processes or the like. And bonding the layers together.

If such an acquisition layer is required for an article using the absorbent core assembly, as described in block 246 of FIG. 23, then an optional fluid acquisition layer 85 is placed over the absorbent core assembly 24. In the exemplary embodiment of the absorbent underwear or pants 20, a fluid acquisition layer is provided.

As described in block 248 of FIG. 23, when the resulting absorbent core assembly is used in absorbent underwear or pants 20, the impermeable barrier layer 78 is such that the barrier layer is furthest away from the wearer's body. Is preferably located below the second section 88. The barrier layer may be an SMS (Spunbond/Meltblown/Spunbond) laminate, or a 23 micrometer (0.9 mil) polypropylene, polypropylene or similar barrier or “microporous breathable film”. It may be in the form. Depending on the material chosen, this film or barrier may be ultrasonically or adhesively bonded to the lower surface of the second section 88. Although it is preferred to incorporate a barrier layer on the underside of the second section of the core, it should be noted that the use of such a barrier layer is not mandatory, but rather optional.

Attempts to use an absorbent core assembly, such as just described, in an absorbent article such as underwear, a diaper or the like, wherein the absorbent article includes an absorbent undergarment or elastic riser gather 106 such as pants 20. If so, creating the absorbent core assembly 24 described above includes additional steps such as those described in block 250 of FIG. In particular, the web of coversheet 76 having the perimeter of the elastic thread 82 as described above can be delivered from the reel and placed over the absorbent core assembly. In addition, a web of permeable nonwoven material for wrapping a portion of the composite absorbent core is delivered from another reel. The web for wrapping may be a barrier layer such as an SMS (spunbond/meltblown/spunbond) laminate or 23 micrometer (0.9 mil) polypropylene, polypropylene or similar barrier or "microporous breathable film". Has a central portion in the form of Depending on the material chosen, the film or barrier may be ultrasonically or adhesively bonded to the underside of the wrapping web. The sides of the wrapping web are further wrapped around the sides of the core and are adhesively secured to the cover sheet 76 adjacent the rising leg gathers 106. Thus, the wrapping web and cover sheet together form a wrap around the top, bottom and sides of the composite absorbent core, with rising leg gathers above the composite absorbent core (first section). Project to.

It should be pointed out at this stage that the top or first section 84 of the composite absorbent core may, if desired, include only a single quilt layer containing SAP 98. Alternatively, the first section 84 may include more than two layers, which may be fabricated in the same manner as described above to enhance total absorption capacity and performance attributes. An additional layer of slow acting but high capacity SAP may be added to increase the total absorption capacity. Preferably, the composite absorbent core comprises only one layer of fast acting but low volume SAP in the layer furthest from the body. Fast acting SAPs tend to exhibit the phenomenon of gel blocking. That is, the outer SAP particles absorb and swell, but prevent further fluid transfer of the same SAP particles to the inner layer. The structure of the composite absorbent core of the present invention overcomes this gel blocking phenomenon by underfilling the absorbent pockets and ensuring that all SAP is exposed to fluid. Utilizing a second layer of this fast acting but gel-blocking SAP on top of the first layer can limit fluid passage through the bottom layer further away from the body layer.

Also, if the edges are tacked in an ultrasonic tacking configuration, a narrower alternative material layer may be inserted between the layers and between the tack bonds. Examples of such materials include airlaids composed of compressed fluff pulp, and/or pulp/SAP, cotton-containing webs, unfibred pulp rolls, or other similar wicking materials added between layers, Fluid transfer to both ends may be facilitated. Other materials such as through-air bonded card webs, 3D perforated films, spunlaces and the like may be incorporated instead to aid in fluid transfer to the layers rather than directly absorbing the fluid itself. Of course, if the layers are adhesively bonded together, full width material may be inserted between the layers if desired. It is also known to use cut-and-place units to incorporate shorter lengths of insert material. These materials are usually incorporated between the upper layer of slow acting but high capacity SAP and the lower layer of the fast acting but low capacity SAP or away from the body. When there are multiple upper layers of slow acting but high capacity SAP, the wicking material described above remains on top of the fast acting but low capacity SAP.

The method of forming a composite absorbent core as just described is preferably such that the indeterminate web of the first or top section 84 is assembled as described above and the indeterminate web of the second or bottom section 88 is Assembled as described above, all of the webs/layers being joined together to form a continuous web that can be processed (eg, cut) to form a series of composite core assemblies. It should be pointed out at this stage that both of the webs are realized on a production processing line provided with a wicking layer 86 of indefinite length. Thus, the continuous web assembled by the joining of the webs of the first section, the second section and the wicking layer serves as a precursor for making a plurality of absorbent core assemblies therefrom. To that end, the precursor web may be wound on a reel 354, as illustrated in FIG. Further, the precursor web may be festooned or assembled so that it can be easily drawn on a production processing line that forms a series of composite absorbent cores that can be used with any type of absorbent product. Good. For example, a reel of precursor core material may be sequentially cut or sectioned to form a series of composite absorbent cores, each of which may be applied to a series of bodies on a continuous assembly line to produce a series of absorbent cores. Underwear or pants 20 can be formed.

That should be pointed out at this stage.
Alternatively, using a web of precursor core material, infant diapers, infant pants diapers, adult protective underwear, adult pants, BCP pads, bed pads, feminine hygiene pads, pet pads, wound pads and Other absorbent products can be formed, such as other absorbent articles.

As will be appreciated by those skilled in the art, making an absorbent core off-line requires additional labor to manage the additional off-line process of making the absorbent core structure. Therefore, it is desirable to use a process that works directly on the final processing machine. The process described above offers that advantage. Thus, the composite absorbent core precursor web described above is suitable for being passed through a processing production line instead of the previous pulp/SAP absorbent structure previously used in such production lines.

Referring now to FIG. 24, an exemplary method of making a body for use with the exemplary absorbent underwear or pants 20 will now be described. In particular, a nonwoven non-woven breathable fabric, such as a web of spunmelt polypropylene or spunmelt polyethylene, or spunmelt polyester, is sequentially cut to form a series of sheets or shells 26. Each of the sheets 26 has a profile like that shown in FIGS. 2 and 2A to form an outer sheet of absorbent underwear or pants 20, as described in block 252. In particular, the outer sheet is preferably laminated to a barrier film-like material that is liquid impermeable, as described in block 254. The inner surface of each of the outer sheets 26 is sprayed with a layer of adhesive 30 as described in block 256. The layer of adhesive is then provided with a number of pre-stretched elastic fibers 32, as described in block 258. These pre-stretched elastic fibers extend across the width of each of the sheets 26 in the areas shown in FIGS. 1, 2 and 2A. Other pre-stretched elastic fibers 68 and 70, as described in block 260, are also provided so that they extend along the portion of the outer edge of the sheet 26 and over the other portion of the sheet 26, as shown in FIG. , Provided on the adhesive layer.

A web of nonwoven breathable fabric, such as spun melt polypropylene or spun melt polyethylene, or spun melt polyester, is sequentially cut to form a series of sheets or shells 28. Each of the sheets 28 has the same contour as the sheet 26 and forms an inner sheet of absorbent underwear or pants 20. Sheet 28 is laminated to sheet 26, where the two sheets are joined together and interposed between the sheets, as described in block 262, to hold elastic fibers 32 in place. Form a sandwich with 68 and 70. Once that is achieved, a calibrated rotating cutter is brought into engagement with each sandwich at selected areas of the sandwich where the composite absorbent core 24 is installed. The calibrated rotary cutter provides a gap 80 between the segments, as described in block 262, without damaging the sheets 26 and 28, to allow closely spaced elastic fibers in that region of each sandwich to form multiple segments. Apply enough force to split into.

Instead of using multiple elastic fibers 32 in the body, a single elastic film sheet of the same overall size and shape of the inner and outer sheets of the body, or whether stacked or spaced apart from each other It should be pointed out at this stage that it is contemplated that multiple sections of elastic film may be provided, regardless, to surround the overall size and shape of the inner and outer sheets. The elastic film or section of elastic film may be interposed between the inner and outer sheets of the body and glued or heat set. Sections of elastic film could be overlapped where greater elasticity is desired. In any case, the portion of the elastic film at the location of the body where the absorbent core assembly is installed is that the elastic film does not tend to collapse or buckle the core assembly, thereby hiding the aesthetics of the undergarment. And there should be a gap there to contribute to comfort. The formation of gaps in the elastic film sheet can be accomplished in a variety of ways, for example by simply spacing the sections of the elastic film or by cutting the elastic film by any suitable means such as a calibrated cutter. It can be realized by engaging.

Thus, each body is ready to secure each absorbent core assembly 24 to the body. To that end, an adhesive is applied to the portion of each body, i.e. the crotch region, where the absorbent core assembly is to be installed, and then each absorbent core assembly is applied thereto and adhesively secured to the body. Each body to which the absorbent core assembly is secured is then adjacent to the dorsal edges or ears 58 and 62, respectively, such that the portions of the body that are adjacent to the anterior edges or ears 48 and 52 are overlapped. The portions of the body that are being stacked are folded and folded, whereupon the overlapping portions of the body are sealed together at the seal line 66 by any suitable means, such as ultrasonic bonding, thermal bonding, adhesive bonding, etc. It This action completes the formation of the pants 20.

Other methods of forming the absorbent core assembly according to the invention are contemplated. Certain such alternatives should increase the efficiency of the process. To that end, if desired, the SAP pocketed layer forming the absorbent core assembly may be structured to be wider than the desired final absorbent core assembly width utilized in the absorbent undergarment. For example, a machine with a width of 1, 2, 3 meters or more can pull out a layer of nonwoven, apply SAP as described above, then add a top layer and then emboss the entire web to remove SAP. Partially filled ultrasonic coupling pockets can be formed. The wide web material may also be ultrasonically cut into multiple layers and edge bonded with an ultrasonic slitter bonder or the like so that the edges are simultaneously cut and bonded. This action creates multiple slits of the desired width in the final product, which results in a process that is substantially more efficient and costly with the same quality as the absorbent layer with SAP-filled pockets that are individually formed at one time. Get lower.

An alternative to the ultrasonic process would be to utilize adhesive bonding instead of, or in combination with, ultrasonic bonding. The layer with SAP pockets will maintain the same partially filled pockets of SAP as described above. Moreover, this construction does not require the SAP embossing pockets to be the same size across the web. If desired, depending on the design and construction of the absorbent product chosen, the size of the pockets may be as desired to ensure that each slit of the single layer absorber can contain SAP along the edges of the slit. You can change it.

Each of the absorbent layers may be created on a one-pass machine or a single layer machine using the methodology described above. The amount of SAP and SAP or the amount of SAP or SAP may then be modified, encapsulating the modified material layer and embossing the optimized pocket pattern modified to suit the desired absorbent product structure. To do. It is further contemplated that layers of width cut from this example process will be staged/stored until all desired layers have been fabricated and made available for assembly to follow. It These rolls of bonded SAP pocketed webs may then be assembled in a subsequent machine or process. It is contemplated that the process will overlay at least two or more layers and then bond them together. Bonding may be done by ultrasonic bonding or thermal bonding using similar materials or known heat-compatible materials. Alternatively, adhesive or other bonding methods may be employed when incorporating either similar or different materials. In either case, this process also allows a narrower web to be added in the middle of the bond points in the middle of the layers. Another alternative is to use a web that is twice as wide as the final product and fold it, for example. Also, if desired, insertion of any desired material (eg, wicking layer) may be added between the folded layers.

Another method contemplated by the present invention uses a unitary or unitary web that includes longitudinally extending quilt-like parallel lines that define quilt layers 90, 92 and 88, the unitary web being shown in FIG. Folding into a generally “G” shaped cross section, as shown, instead of using three separate quilt layers 90, 92 and 88, the streaks defining the quilt layer 90 overlap the quilt layer 92, This further overlays the quilt layer 88 and further secures it together as described above. A system for performing such an alternative method is shown in FIG. To this end, as can be seen, a reel 400 of the same nonwoven material is provided that makes up the upper and lower sections 84 and 88, respectively. However, the width of the material on that reel is equal to the overall width of the webs 90, 92 and 88. This triple width web material 402 is fed under three SAP particle feeders 404, 406 and 408. The particle feeder 404 streaks 410 a highly absorbent, slow acting SAP 98 in the upper surface of the web 402 and in the area that occupies one third of the width of the web 404 and is adjacent to one side edge of the web. Configured for spraying or spraying. The particle feeder 406 streaks 412 high absorbency, slow acting SAP 98 in the upper surface of the web 402 and in the area that occupies one third of the width of the web 404 and is adjacent the opposite side edge of the web 402. Configured for spraying or spraying. The particle feeder 408 sprinkles the low absorbency, fast acting SAP 100 on the upper surface of the web 402 and the area occupying the middle third of the width of the web 404 between the stripes 410 and 412 in stripes 414. Or configured to be sprayed. Another reel 416 is provided that holds a roll of web 418 that is identical to web 402. The web 418 is withdrawn so that the webs 418 extend and are located on the web 402 downstream of the area on which the webs 410, 412 and 414 of the web 402 have been sprinkled or sprayed with SAP. The two webs 402 and 418 are then fed to a sealing station 420, which is preferably in the form of ultrasonic rollers. The roller seals the webs together to form a diamond-shaped pocket for the SAP. In particular, the striations 410 of the web 402 are sealed by the sealing station 420 along with the overlap of the web 418 to form a quilt layer 92 partially filled with loose SAP98 in its diamond-shaped pocket. Similarly, the streaks 412 of the web 402 are sealed by the sealing station 420 along with the overlap of the web 418 to form a quilt layer 90 partially filled with loose SAP98 in its diamond-shaped pocket. .. Similarly, the streaks 414 of the web 402 are sealed by the sealing station 420 together with the overlap of the web 418 to form a quilt layer 88 partially filled with loose SAP100 in its diamond-shaped pocket. ..

The sealing station 420 seals the portion of the web forming the quilt layer 92 and separates it from the portion of the web forming the quilt layer 88 and seals the portion of the web forming the quilt layer 90. The web is also longitudinally sealed so as to separate from the portion of the web that forms layer 88.

The composite web exiting the sealing station 420 then passes past the folding table 422, where the composite web is folded into the generally G-shaped cross-sectional shape shown in FIG. In particular, the portion of the composite web that exits the sealing station to form quilt layer 92 is folded over the portion of the composite web that forms quilt layer 88, and the portion of the composite web that forms quilt layer 90 forms quilt layer 92. Is folded onto the composite web portion. If desired, a second material may be added between the folded parts. For example, if the absorbent core assembly is intended to include the wicking layer 86 described thus far, a web of material from which it is made can be inserted between layers 88 and 92. In either case, the assembled composite web exiting the folding table 422 is provided to a tack bonder unit 424 including an ultrasonic roller to seal the perimeter of the composite web. The edge-sealed composite web exiting the bonding unit 424 can then be wound onto a reel 426 for subsequent use.

As will be appreciated by those skilled in the art, one-pass wide machines generate individual labor costs for each web layer produced. The additional processing costs and the subsequent separate process for constructing the layers incur additional labor costs. Therefore, the use of wide, multi-layer machines is a more desirable way to reduce duplication of labor costs for the same volume of material. To that end, the multi-layer machine is provided with at least two or more superabsorbent material delivery systems, multiple bond layer drawing stations, embossing rolls, ultrasonic bonders, slitters, bonders for a composite absorbent core for finishing. And should include a winder. For example, using such a machine to create the layer furthest away from the body, the machine pulls out a layer of non-woven barrier-like material or film, applies SAP, and is a permeable bondable fabric. A second layer on top and then bonded to form a quilt layer having pockets partially filled with SAP. Then, after the first stage, a similar application would be executed. In its second step operation, the permeable nonwoven is drawn into the bottom layer of the process, SAP is applied to the bottom layer, another tie layer is incorporated on top and then bonded and partially filled SAP Recreate the pocket quilt layer. These two layers can be aligned on top of each other and scored and edge bonded to create the final absorbent structure. A third layer or additional layers can be made similarly. Again, it is then bonded and cut to size when rolling up the final absorbent core area of the process. In this process, additional withdrawal stations for non-ultrasonic bondable material may be added. For example, if a 12.7 centimeter (5 inch) wide absorbent core is desired, an intermediate layer of bonded pocket SAP selective layers may be added with a narrower 5.08 centimeters of airlaid absorbent wicking layer. A (2 inch) notch is desired. At this additional draw station, a 5.08 cm (2 inch) airlaid was centered and drawn directly as desired, 3.81 cm (1 inch) on each side of the airlaid material, centered between the layers. 0.5 inch spacer is added. The layered rolls ultimately bonded together may be rolled, festooned, or assembled so that they are easily drawn into the production processing line.

Fabricating an indefinite length web of absorbent core assembly 24 about 5 inches (5 inches) wide, and then 46.64 to secure each piece of body in a series to form each undergarment or pant. It was pointed out at this stage that it is contemplated to fabricate the absorbent core "sideways" to feed a series of bodies, instead of cutting it to a length of 55.88 cm (16-22 inches). Should be kept. In that alternative configuration, the indeterminate length web of the absorbent core assembly is provided with a width of 46.64 to 55.88 cm (16 to 22 inches), followed by a series of 12.7 cm (5 inches) wide sections. Will be cut into. Each of the resulting sections of 46.64-55.88 cm (16-22 inches) long by 12.7 cm (5 inches) wide could then be secured to each individual body in the series. Such a configuration should better adjust the absorbent core assembly to future mechanical designs for making absorbent underwear. By using such an alternative sideways core assembly feeding technique, the material that makes up the wicking layer, which is only about 5.08 cm (2 inches) wide, is made up of 46.64-55.88 cm (16. It should be appreciated that it is necessary to apply streaks that are sequentially spaced across the width of a web that is ~22 inches wide, each of which is approximately 7.62 cm (3 inches) from the next successive strip. Are spaced apart. Thus, a web of 16 to 22 width can be cut sequentially in the middle of the streaks of sequentially spaced wicking layers, thereby centering a 5.08 cm (2 inch) wide wicking layer for fixation to each body. A series of 46.64 to 55.88 centimeters (16 to 22 inches) long by 12.7 centimeters (5 inches) wide absorbent core assemblies can be fabricated, each having.

Also, as will be appreciated by those skilled in the art, an ultrasonic bonding unit is utilized to form each quilt layer of the composite core, and at the very end, to tack or bond all the quilt layers together. Utilizing one ultrasonic coupling unit is somewhat costly. Therefore, it is contemplated to utilize one ultrasonic coupling station only at the end of the process to reduce the capital cost of multiple ultrasonic stations. Adhesion of various webs with SAP will be very important throughout the process until the final bonding station. The station will create diamond-shaped pockets and fuse the edges to prevent SAP from falling out while simultaneously bonding all layers together. This composite core could then be used to pass through a process production line as an alternative to the previous pulp/SAP absorbent structure previously used in such production lines.

Other combinations of the above methods are contemplated. For example, a layer of spunbonded fabric may be corrugated or folded to increase the surface area, making the SAP more area for expansion. This can be done in one or more layers. This composite core would then pass through a processing production line as an alternative to the previous pulp/SAP absorbent structure previously used in such production lines.

In a production processing line, the absorbent core of the invention described above may be marketed by feeding it at the tissue unwrap/fluff end of the machine instead of the acquisition layer module that can be fed from the side or from above. Any machine that is or will be developed in the future is suitable for utilizing the composite absorbent cores of the present invention may be used in place of existing pulp/SAP absorbent cores.

When bonding multiple layers of partially filled SAP pockets together, the absorption function and softness should be carefully controlled. In this regard, the absorbent function can be adversely affected when using a global adhesive bond or a global thermal bond approach to bond the layers together. These approaches may create a barrier that hinders and slows the rate of absorption in the absorbent core structure of the present invention. Therefore, it is very important that such a structure does not hinder the flow of fluid. If edge bonding is employed, it should be managed to prevent stiffness or hard edges along both sides of the absorbent body. The sides of these hard edges will be perceptible and uncomfortable for those who wear absorbent cores structured with continuous bonds. Therefore, in the composite layer absorbent core structure of the present invention, intermittent bonding away from each side is desirable. Such a bond eliminates the stiffness of the continuous bond and does not impede fluid flow through the central portion of the absorbent core. Furthermore, if the intermittent couplings on each side are staggered, i.e. spaced offset rather than parallel to each other, such a configuration provides softness and softness while maintaining acceptable stiffness and flatness of the absorbent core. It will promote comfort. This will help a well structured, comfortable and consumer desirable absorbent product appearance.

Without further elaboration, the above description is sufficient to describe our invention, so that others may apply it under various conditions of use by applying their present or future knowledge. Could be adopted for

Claims (62)

A disposable absorbent undergarment adapted to be worn by a person, said undergarment comprising:
An absorbent core assembly having a predetermined width and configured to absorb fluid from a person;
A main body having a sheet of cloth-like non-woven breathable material,
The seat has an inner surface, a front portion, a back portion, and a crotch portion positioned between the front portion and the back portion,
The front portion has an upper front edge, a pair of front side edges, and a plurality of elastic threads, and the plurality of elastic threads extend parallel to the upper front edge and are parallel to each other from one of the pair of front side edges. Extends to the other of the pair of front side edges,
The back portion has an upper back edge, a pair of back side edges, and a plurality of elastic threads, and the plurality of elastic threads extend parallel to the upper back edge and are parallel to each other. To the other of the pair of dorsal edges,
The crotch portion has a pair of center side edges and a plurality of elastic threads, and the plurality of elastic threads extend in parallel to the upper front edge and the upper back edge, and are parallel to each other in the pair of center side edges. Extending from one to the other of the pair of central side edges,
Each of the front side edges is fixed to the back side edge,
Each of the pair of central side portions comprises an ergonomically shaped recess forming each leg opening for a human being,
The recesses are spaced from each other by a distance greater than the predetermined width of the absorbent core assembly,
The absorbent core assembly includes the core on the inner surface of the body at the crotch between the leg openings to prevent the core from collapsing or buckling as the undergarment is worn by a person. An undergarment secured using a plurality of threads of the plurality of elastic threads of the crotch portion of the absorbent core assembly that are divided into separate sections at. The plurality of elastic threads of the front portion extend from a point closely adjacent to the upper front edge to the intermediate portion and are closely spaced from each other, where the front portion has a minimal pleated appearance. The plurality of elastic threads of the back portion extend from a point closely adjoining the upper back edge to the intermediate portion and are closely spaced from each other, where the back portion has a minimum pleated appearance. The underwear according to claim 1, which is present. The underwear of claim 2, wherein the spacing between adjacent elastic threads is in the range of about 4-5 mm. The underwear of claim 2, wherein the elastic threads are colored to be easily visible from the outer surface of the underwear. The underwear includes a waistband portion adjacent to the upper front edge and the upper back edge, and the waistband portion includes a plurality of waistband elastic threads extending parallel to the upper front edge and the upper back edge. Wherein the waistband elastic yarn has a greater degree of tension or stretchability than the elastic yarn in the portion of the body between the waistband portion and the crotch portion. underwear. The underwear according to claim 5, wherein the elastic threads of the portion of the body between the waistband portion and the crotch exhibit a decreasing tension or stretch gradient toward the crotch. 7. Underwear according to claim 6, wherein the tension or stretch gradient comprises at least three zones of different tension or stretch. The absorbent core assembly comprises a first section and a second section, the first section being formed from at least one layer of porous material configured to allow movement of liquids. , The at least one layer of porous material of the first section is quilted to form a plurality of first pockets, each of the first pockets having a slow acting but high absorption capacity. Partially free of SAP, the second section is located below the first section and has a predetermined width and length, and the second section is Formed from a layer of porous material configured to allow movement, wherein the porous material of the second section is quilted to form a plurality of second pockets, and the second Each of the pockets is partially filled with fast acting but low absorption capacity of free SAP, and the first section of the absorbent core assembly and the second section of the absorbent core assembly are: While in fluid communication with each other, the first section of the absorbent core assembly forms a body-facing side that is positioned facing the perineal area of the person, and fluid excreted by the person is the fast acting SAP. And to the slow acting SAP, the fluid is quickly and rapidly absorbed by the fast acting SAP, while the slow acting SAP desorbs or removes fluid from the fast acting SAP and removes the fluid itself. The underwear of claim 1, which absorbs. The undergarment of claim 8, wherein the absorbent core assembly further comprises an intermediate wicking layer disposed between the first and the sections. The underwear of claim 9, wherein the wicking layer comprises an airlaid material. The undergarment of claim 8, wherein the core comprises a fluid acquisition layer disposed over the first section of the core. The volume of at least some SAPs of the first pocket is in the range of about 25 to 35 percent of the volume of the first pockets, and the volume of at least some SAPs of the second pockets is the second pockets. The undergarment of claim 8, wherein the undergarment is in the range of about 20 to 30 percent of its volume. The first section of the core has a predetermined width and length, the second section of the core has a predetermined width and length, and the core includes the first and An intermediate nonwoven fluid transfer layer having a predetermined width that is less than a predetermined width of the second section, the intermediate nonwoven fluid transfer layer including fluid transfer between the first section and the second section. The underwear of claim 8, wherein the undergarment is positioned between the first section and the second section to encourage movement. The first section comprises a first layer of porous material and a second layer of porous material, each of the first layer and the second layer configured to allow movement of liquid. In addition, a plurality of first pockets are formed in the first layer and a plurality of first pockets are formed in the second layer by being quilted by a fixedly attached fixing line, and each of the first pockets has a low speed The undergarment of claim 8, which is partially filled with a functional but high absorption capacity of free SAP. An absorbent core for an absorbent underwear worn by a person, wherein the core is
A first section formed of at least a first layer and a second layer, each of the first layer and the second layer formed of a porous material configured to allow movement of a liquid. A plurality of first pockets are formed in the first layer and a plurality of first pockets are formed in the second layer by being quilted by fixedly attached fixing lines, and each of the first pockets has a low speed The working but high absorption capacity of free SAP is partially filled and the volume of at least some of the SAPs of the first pocket of the first layer is equal to the volume of the first pocket of the first layer. Is about 25 to 35 percent, and the volume of at least some SAPs in the first pocket of the second layer is about 80 times the volume or amount of SAP in the first pocket of the first layer. -120% and within the range of 25 to 35% of the volume or volume of the first pocket of the second layer, the first section being located facing the perineal region of the person. A first section forming a body-facing side,
A second section located below the first section and in fluid communication with the first section, the second section having a predetermined width and length; The section is formed from a layer of porous material configured to allow movement of liquid, the layer of the second section being quilted to form a plurality of second pockets, Each of the second pockets is partially filled with fast acting but low absorption capacity of free SAP, and the volume of at least some of the SAP in the second pockets is equal to the volume of the second pockets. Is about 20 to 30 percent, the core is configured such that fluid excreted by a person flows to the first fast acting SAP and the slow acting SAP, the fluid being formed by the fast acting SAP. A second section that is rapidly and rapidly absorbed, while the slow acting SAP desorbs or removes fluid from the fast acting SAP and absorbs the fluid itself;
An absorbent core. 16. The absorbent core of claim 15, further comprising a fluid transfer or wicking layer disposed between the first section and the second section. The first section comprises a third layer formed of a porous material configured to allow movement of fluid and quilted by a rigid fixation line to form a plurality of first pockets. The volume of at least some SAPs in the first pocket of the third layer is in the range of about 80 to 120 percent of the volume or amount of SAP in the first pocket of the first layer, and 17. The absorbent core of claim 16, which is within the range of 25 to 35 percent of the volume or capacity of the three layers of the first pocket. An absorbent core for an absorbent underwear worn by a person, wherein the core is
A first section formed of at least a first layer and a second layer, each of the first layer and the second layer formed of a porous material configured to allow movement of a liquid. A plurality of first pockets are formed in the first layer and a plurality of first pockets are formed in the second layer by being quilted by fixedly attached fixing lines, and each of the first pockets has a low speed. The working but high absorption capacity of free SAP is partially filled, the SAP of the first section has a vortex time in the range of about 30 to 90 seconds, and the first section is A first section that forms a body-facing side that is positioned facing the perineal area of the person;
A second section located below the first section and in fluid communication with the first section, the second section having a predetermined width and length; The section is formed from a layer of porous material configured to allow movement of liquid, the layer of the second section being quilted to form a plurality of second pockets, Each of the second pockets is partially filled with fast acting but low absorption capacity of free SAP and the second section SAP has a vortex time in the range of about 3 to 10 seconds. The core is configured such that fluid excreted by a person flows to the first fast acting SAP and the slow acting SAP, while the fluid is quickly and rapidly absorbed by the fast acting SAP. In contrast, the slow acting SAP desorbs or removes fluid from the fast acting SAP and absorbs the fluid itself; a second section;
An absorbent core. 19. The absorbent core of claim 18, wherein the ratio of vortex time of said slow acting SAP to said fast acting SAP is in the range of about 6:1 to 3:1. The first section comprises a third layer formed of a porous material configured to allow movement of fluid and quilted by a fixedly attached fixation line to form a plurality of first pockets. 19. The absorbent core of claim 18, wherein each of the first pockets of the third layer is partially filled with slow acting but high absorption capacity of free SAP. An absorbent core for an absorbent underwear worn by a person, wherein the core has a longitudinal axis,
A plurality of first pockets are formed in at least one layer formed from at least one layer of a porous material configured to allow movement of liquid and quilted by a fixedly attached fixation line. A first section of each of the first pockets, each of the first pockets being partially filled with a slow acting but high absorption capacity of free SAP, each of the first pockets comprising a first pair of A diamond shape having diametrically opposite corners and a second pair of diametrically opposite corners, the first pocket being oriented such that the diametrically opposite corners of the first pair extend parallel to the longitudinal axis; A first section, the first section being arranged facing the perineal region of the person, forming the body-facing side;
A second section located below the first section and in fluid communication with the first section, the second section being configured to allow movement of a liquid. Layer of said second section is quilted to form a plurality of second pockets, each of said second pockets having a fast acting but low absorption capacity. Partially filled with free SAP, each of the second pockets is a diamond shape having a first pair of diametrically opposite corners and a second pair of diametrically opposite corners, the second pockets being the first pockets. The pair of diametrically opposed corners are oriented so as to extend parallel to the longitudinal axis, and the core acts in a tortuous path caused by the fluid excreted by a human being caused by the orientation of the diamond-shaped pocket relative to the longitudinal axis. Configured to flow to the SAP and the slow acting SAP, the fluid is quickly and rapidly absorbed by the fast acting SAP, while the slow acting SAP desorbs fluid from the fast acting SAP. Or a second section that removes and absorbs the fluid itself,
An absorbent core. The first section comprises a first layer and a second layer, each of the first layer and the second layer formed from a porous material configured to allow movement of a liquid, A plurality of first pockets are formed in the first layer and a plurality of first pockets are formed in the second layer by being quilted by fixedly attached fixing lines, and each of the first layer and the second layer is formed. Each of said first pockets is diamond-shaped with a first pair of diametrically opposite corners and a second pair of diametrically opposite corners, wherein said first pockets of said first and second layers are 22. The absorbent core of claim 21, wherein the pair of diametrically opposed corners are oriented to extend parallel to the longitudinal axis. 22. The absorbent core of claim 21, wherein the diamond shaped pocket is square and ranges from about 1.5 cm x 1.5 cm to 3.0 cm x 3.0 cm. An absorbent core for an absorbent underwear to be worn by a person, wherein the absorbent core has a longitudinal axis,
A first absorbent section formed of a porous material having a first pair of longitudinally extending side edges, the first absorbent section being configured to allow movement of a liquid. A first and a second layer, wherein the first layer is disposed on the second layer, and each of the first layer and the second layer is fixedly attached to a fixed wire. Quilted to form a plurality of first pockets therein, the first pockets of the first layer being partially filled with slow acting but high absorption capacity of free SAP, The first pocket of the second layer is installed between the outer first pocket and the outer first pocket that are installed in close contact with each of the pair of longitudinally extending side edges. An inner first pocket, each of the outer first pockets being partially filled with SAP that has a slow action but a high absorption capacity, and each of the inner first pockets has a low velocity. The free but high absorption capacity of SAP is partially filled and the volume of SAP in the outer first pocket is greater than the volume of SAP in the inner first pocket and the first section is A first absorbent section, which forms a body-facing side, which is arranged facing the perineal area of the person;
A second absorbent section located below the first absorbent section and in fluid communication with the first section, the second section being formed from a layer of porous material, The layer of the second section is configured to allow movement of liquid and is quilted to form a plurality of second pockets, the second pockets having a high speed action but a low velocity. The absorbent capacity is partially filled with SAP, and the core is configured such that fluid excreted by a person flows to the first fast acting SAP and the slow acting SAP, and the fluid is the fast acting SAP. A second absorbent section that is rapidly and rapidly absorbed by the working SAP, while the slow acting SAP desorbs or removes fluid from the fast acting SAP and absorbs the fluid itself;
An absorbent core. The first section comprises another layer formed of a porous material configured to allow movement of liquid, the another layer being quilted by a fixedly attached fixation line. Forming a plurality of first pockets therein and each of the first pockets of the other layer is partially filled with a slow acting but high absorption capacity of free SAP. Item 24. The absorbent core according to Item 24. 25. The absorbent core of claim 24, wherein the outer first pocket occupies about two-thirds of the width of the first absorbent section. 25. The absorbent core of claim 24, further comprising a fluid transfer or wicking layer disposed between the first absorbent section and the second absorbent section. An absorbent core for an absorbent underwear worn by a person, wherein the core has a longitudinal axis,
A first absorbent section formed from a first layer of porous material and a second layer of porous material, the first layer being configured to allow movement of liquid and immobilizing Quilted by an attached fixed line to form a plurality of first pockets in the first layer, the second layer being disposed under the first layer and allowing movement of liquid. And the second layer is quilted by a fixedly attached fixation line to form a plurality of first pockets in the second layer. Each of the first pockets is partially filled with slow acting but high absorption capacity of free SAP, and at least some of the first pockets of the second layer also contain deodorant material. Absorbable section, the first layer of the first section forming a body-facing side disposed facing the perineal region of the person;
A second absorbent section located below the first absorbent section and in fluid communication with the first section, the second section being formed from a layer of porous material, The layer of the second section is configured to allow movement of liquid and is quilted to form a plurality of second pockets, the second pockets having a high speed action but a low velocity. The absorbent capacity is partially filled with SAP, and the core is configured such that fluid excreted by a person flows to the first fast acting SAP and the slow acting SAP, and the fluid is the fast acting SAP. A second absorbent section that is rapidly and rapidly absorbed by the working SAP, while the slow acting SAP desorbs or removes fluid from the fast acting SAP and absorbs the fluid itself;
An absorbent core. 29. The absorbent core of claim 28, further comprising a fluid transfer or wicking layer disposed between the first section and the second section. The first section comprises another layer formed of a porous material configured to allow movement of liquid, the another layer being quilted by a fixedly attached fixation line. Forming a plurality of first pockets therein and each of the first pockets of the other layer is partially filled with a slow acting but high absorption capacity of free SAP. Item 29. The absorbent core according to Item 28. A method of making a disposable absorbent undergarment adapted to be worn by a person, the method comprising:
A first sheet of non-woven fabric breathable material, the first sheet comprising an inner surface, a front portion, a back portion, a crotch portion positioned between the front portion and the back portion, and the front, back and An absorbent core receiving region including a crotch portion, the front portion including an upper front edge and a pair of front side edges, and the back portion including an upper back edge and a pair of back side edges. And the crotch portion comprises a pair of central side edges, each of the pair of central side portions being ergonomically shaped to form a respective leg opening for a human. A first sheet comprising a recess, the recesses being spaced from each other by a first distance;
A plurality of pre-stretched elastic threads fixed to the first sheet, wherein the plurality of pre-stretched elastic threads are parallel to the upper front edge and to each other from one of the pair of front side edges to the pair of front side edges. A first plurality of pre-stretched elastic yarns extending to the other, and a second plurality of pre-stretched elastic yarns extending from one of the pair of back side edges to the other of the pair of back side edges in parallel with each other on the upper back edge and each other. A plurality of pre-stretched elastic yarns extending from one of the pair of center side edges to the other of the pair of center side edges in parallel with each other, the upper front edge, the upper back edge and each other. Elastic thread,
Providing a body comprising
Dividing a plurality of the plurality of pre-stretched elastic yarns into separate sections at the location of the absorbent core receiving area;
Providing an absorbent core assembly configured to absorb fluid from a person and having a width less than the first distance;
Securing the absorbent core assembly to the inner surface of the body between the absorbent core receiving section and each leg opening;
Fixing each of the front edge to each of the back edge;
Including the method. 32. The method of claim 31, wherein the spacing between adjacent elastic threads is in the range of about 4-5 mm. The plurality of pre-stretched elastic yarns of the front portion extend from a point closely adjoining the upper front edge to the intermediate portion, and the plurality of elastic yarns of the back portion closely contact the upper back edge. 32. The method of claim 31, extending from an adjacent point to the middle portion. 32. The method of claim 31, wherein the pre-stretched elastic yarn is tinted for easy viewing from the outer surface of the undergarment. The underwear includes a waistband portion adjacent to the upper front edge and the upper back edge, and the waistband portion includes a plurality of pre-stretched waistbands extending parallel to the upper front edge and the upper back edge. An elastic thread is provided, and the pre-stretched waist band elastic thread has a greater degree of tension or elasticity than the pre-stretched elastic thread of the portion of the main body between the waist band portion and the crotch portion. 32. The method of claim 31, comprising. 36. The method of claim 35, wherein the pre-stretched elastic yarn of the portion of the body between the waistband portion and the crotch exhibits a decreasing tension or stretch gradient toward the crotch. .. 37. The method of claim 36, wherein the tension or stretch gradient comprises at least three zones of different tension or stretch. The absorbent core assembly comprises a first section and a second section, the first section being formed from at least one layer of porous material configured to allow movement of liquids. , The at least one layer of porous material of the first section is quilted to form a plurality of first pockets, each of the first pockets having a slow acting but high absorption capacity. Partially free of SAP, the second section is located below the first section and has a predetermined width and length, and the second section is Formed from a layer of porous material configured to allow movement, wherein the porous material of the second section is quilted to form a plurality of second pockets, and the second Each of the pockets is partially filled with fast acting but low absorption capacity of free SAP, and the first section of the absorbent core assembly and the second section of the absorbent core assembly are: 32. The method of claim 31, in fluid communication with one another, wherein the second section of the absorbent core assembly is located closer to the body than the second section of the absorbent core assembly. 39. The method of claim 38, wherein the absorbent core assembly further comprises an intermediate wicking layer disposed between the first section and the second section. 40. The method of claim 39, wherein the wicking layer comprises an airlaid material. 39. The method of claim 38, wherein the absorbent core assembly comprises a fluid acquisition layer disposed over the first section of the core. The main body further includes a second sheet having the same size and shape as the first sheet, and the main body is
Applying a layer of adhesive on at least one surface of the first and second sheets;
Arranging the plurality of pre-stretched elastic threads in the layer of adhesive,
Bringing together the first and second sheets to sandwich the plurality of pre-stretched elastic yarns between the first and second sheets;
32. The method of claim 31, formed by. 43. The method of claim 42, wherein the layer of adhesive is applied to the inner surface of a second sheet. 44. The method of claim 43, wherein the second sheet further comprises a liquid impermeable barrier layer. The absorbent core assembly is
Providing a first section of at least one layer of porous material configured to allow movement of liquid;
Quieting the at least one layer of the first section by a fixedly attached fixation line to form a plurality of first pockets, each of the first pockets having a slow acting but high absorption capacity. Quilting, partially filling the first volume of SAP;
Providing a second section of at least one layer of porous material configured to allow movement of liquid;
The at least one layer of the second section is quilted by a fixedly attached fixation line to form a plurality of second pockets, each of the second pockets having a fast acting but low absorption capacity. Quilting, partially filling a second volume of the SAP different from the first volume;
The first section is disposed above the second section such that they are in fluid communication with each other, and the core obtained therein is such that the fluid contacting the first section is the porous material of the first section. Through said at least one layer of said first pocket into said second pocket through said at least one layer of said second section, whereupon said fast acting SAP rapidly and rapidly While the slow acting SAP desorbs or removes liquid from the fast acting SAP and absorbs the liquid itself.
32. The method of claim 31, created by. The first volume of slow acting but high absorption capacity SAP is free in the first pocket, and the second volume of fast acting but low absorption capacity SAP is in the second pocket. 46. The method of claim 45, which is free of The first section includes two layers, each of the layers of the first section comprising a plurality of the first pockets containing a portion of the slow acting but high absorption capacity SAP. Item 45. The method according to Item 45. 46. The method of claim 45, wherein the pocket is formed by ultrasonic bonding or thermal bonding or adhesive bonding. 46. The method of claim 45, further comprising providing a wicking layer disposed between the first and second sections to enhance liquid transfer between the first and second sections. 46. The method of claim 45, further comprising providing a fluid trapping layer disposed over the first section. A method of making an absorbent core assembly, the method comprising:
Providing a first continuous web of porous material configured to allow movement of a liquid.
Providing a second continuous web of porous material configured to allow movement of liquid;
Applying a high absorption capacity SAP to the surface of the first continuous web by slow action;
Firmly bonding the first and second webs together to form a first quilt web, wherein the first quilt web has a free volume of SAP with the slow acting high absorption capacity. Comprising a plurality of pockets each of which is partially filled, providing a secure connection,
Providing a third continuous web of porous material configured to allow movement of liquid;
Providing a fourth continuous web of porous material configured to allow movement of liquid;
Applying a high absorption capacity SAP to the surface of the third continuous web by slow action;
Firmly joining the third and fourth webs together to form a second quilt web, wherein the second quilt web has a free volume of the slow acting high absorption capacity, respectively. Secure coupling, with multiple partially filled pockets;
Disposing the first quilt web over the second quilt web to form a first section of the absorbent core assembly, wherein the first section has a perimeter.
Providing a fifth continuous web of porous material configured to allow movement of liquid;
Providing a sixth continuous web of porous material configured to allow movement of liquid;
Applying a low absorption capacity SAP on the surface of the fifth continuous web at high speed;
Firmly bonding the fifth and sixth webs together to form a third quilt web, wherein the third quilt web has a free volume of the fast acting, low absorption capacity SAP. A plurality of pockets, each of which is partially filled, the third quilt layer forming a second section of the absorbent core assembly, the second section having a perimeter, and securely joining. ,
Providing a web of wicking layer below the first section and above the second section, wherein the web of wicking material is sandwiched between the first and second sections. ,
Sealing the perimeter of the first section to the perimeter of the second section to form a composite web, the composite web being a precursor for making a plurality of absorbent core assemblies. The body, the sealing,
Including the method. 52. The method of claim 51, wherein the plurality of pockets of the first layer and the second layer are offset from each other. 52. The method of claim 51, wherein the bonding of the webs is accomplished by ultrasonic bonding or adhesive bonding. The absorbent core assembly further comprises a fluid trapping layer formed by a web of fluid trapping material, the method further comprising disposing the web of fluid trapping material over the first section. 52. The method of claim 51. The absorbent core assembly further comprises a liquid barrier layer formed by a web of barrier material, the method further comprising disposing the web of barrier material under the second section. The method according to 51. The absorbent core assembly further comprises a liquid barrier layer formed by a web of barrier material, the method further comprising disposing the web of barrier material under the second section. 54. The method according to 54. The absorbent core assembly further comprises a cover layer formed by a web of porous material, the method further comprising disposing the web of porous material over the first section. Item 51. The method according to Item 51. The absorbent core assembly further comprises rising leg gathers formed by a web of material having a plurality of elastic fibers secured thereto, the method comprising: 58. The method of claim 57, further comprising securing to the cover layer. 52. The method of claim 51, wherein the composite web is wound onto a reel for subsequent use. For making multiple disposable absorbent incontinence products, infant absorbent underwear, diapers, sanitary napkins, panty liners, or any other absorbent product configured to absorb liquids from living things 52. The method of claim 51, wherein the composite production line is provided with the composite web. A composite web is provided for making a plurality of absorbent undergarments, each of the undergarments including a body having a receiving area for the absorbent core assembly, the body including first and second sheets. And each of the sheets is of similar size and shape, and the body is
Applying a layer of adhesive on at least one surface of the first and second sheets;
Disposing a plurality of pre-stretched elastic threads in the layer of adhesive,
Bringing together the first and second sheets to sandwich the plurality of pre-stretched elastic yarns between the first and second sheets;
61. The method of claim 60 formed by. 62. The method of claim 61, further comprising dividing a plurality of the plurality of pre-stretched elastic yarns into separate segments at the location of the absorbent core receiving area.