MXPA00010516A - Method of individually packaging a three dimensionally-shaped absorbent article - Google Patents

Abstract

A tube of absorbent material extends outward from the body-facing side of the base pad and is aligned along the longitudinal centerline of the base pad. In one embodiment, the tube of absorbent material comprises an absorbent material and a cover at least partially wrapping the absorbent material. In this embodiment, the absorbent material is penetrated by autogenous bonds that join one portion of the cover to an opposing portion of the cover. The bonds are selectively placed to provide the tube of absorbent material with a distinct three-dimensional shape. The method of making a shaped tube of absorbent material for the sanitary napkin, in one embodiment, involves the steps of:(a) providing a web of absorbent material;(b) providing a cover for the first and second surfaces of the web of absorbent material;(c) at least partially covering the first and second surfaces of the web of absorbent material with the cover to form a composite web having longitudinal side margins;(d) folding the composite web at least once with folds defining fold lines that are arranged about the longitudinal centerline of the web of absorbent material;and (e) autogenously bonding a portion of the cover that covers the first surface of the web of absorbent material to a portion of the cover that covers an opposing portion of the second surface of the web of absorbent material.

Description

METHOD FOR INDIVIDUALLY PACKING A TRIDIMENSIONALLY CONFIGURED ABSORBENT ARTICLE FIELD OF THE INVENTION The present invention relates to a sanitary napkin comprising a tube of three-dimensionally shaped absorbent material and to a method for making the same. Also disclosed is a method for individually packing a three-dimensionally shaped absorbent article.

BACKGROUND OF THE INVENTION Absorbent articles such as sanitary napkins, pantiliners, disposable diapers, incontinence products, and bandages, are designed to absorb and retain liquids and other discharges from the human body and to avoid staining the body and clothing. A need that occurs in the manufacture of absorbent articles is to provide the absorbent article with more complex three-dimensional shapes in an effort to fit more closely to a user's body. In the past, a number of efforts have been made to create articles that conform to the body. One way to provide an absorbent article with a shape that conforms to the body, eg, a triangular cross section for a sanitary napkin, was generally to stack elements on top of each other. Examples of such structures are shown in US Patent 4,340,058 issued to Pierce et al. On July 20, 1982 and US Patent 4,490,147 issued to Pierce et al. On December 25, 1984. Stacking of materials to form absorbent articles three-dimensionally configured suffers from the disadvantage that it is very difficult to carry over high-speed manufacturing processes. This is due to difficulties encountered with the registration and differences in the capacity of extension of the materials (which are usually applied continuously) that are stacked. That is, it is difficult to maintain such materials in the precise degree of alignment with respect to each other that is necessary for stacking. If the continuous webs have different cross-sectional areas, the bands with the smaller cross-sectional area will tend to stretch more in said process under the same amount of force as will the bands having a larger cross-sectional area. Other efforts involved molding the absorbent article, or an element thereof in a configuration that conforms to the body. One of these efforts is described in US Patent 5,197,959 entitled "Absorbent Article", issued to Buell on March 30, 1993. The search for improved absorbent articles that conform to the body and methods for making them, keep going. Thus, there is a need for absorbent articles with complex shapes, which conform to the body, which do not involve stacking elements in various ways other than the desired shape, or to mold an element, in order to form an absorbent article of the desired configuration.

COMPENDIUM OF THE INVENTION The present invention is directed to an absorbent article comprising a tube of three-dimensionally shaped absorbent material and a method for making the same. In a preferred embodiment, the absorbent article is a sanitary composite pad. The composite sanitary napkin comprises a base pad having a side facing the body, a side facing the garment, and a longitudinal center line. The base pad preferably comprises a liquid permeable topsheet, a liquid impermeable backsheet attached to the topsheet, and an absorbent core positioned between the topsheet and the backsheet. A tube of absorbent material is placed on the side facing the body of the base pad and is aligned along the longitudinal center line of the base pad. The tube of absorbent material preferably comprises an absorbent material and a cover at least partially enveloping the absorbent material. The absorbent material is preferably penetrated by autogenous bonds that attach a portion of the cover to a portion of the cover that is provided to provide the tube with a unique three-dimensional configuration. In a particularly preferred embodiment, the tube of absorbent material has a transverse configuration of three lobes. At least in the center of the sanitary napkin. The transverse configuration of three lobes comprises an inverted "T" shaped cross section comprising a straight central lobe symmetrically disposed around the longitudinal center line and two outer lobes. The central lobe has a larger caliber than the two outer lobes, and is preferably able to fit comfortably in the space between the major and minor lips of the user. The present invention is also directed to a method for making a tube of absorbent material configured for the sanitary napkin described above. The method preferably comprises the steps of: (a) providing a web of absorbent material, the web of absorbent material having a length, a width and a longitudinal center line oriented along the length of the web of absorbent material, a first surface and a web; second opposite surface; (b) providing a cover for the first and second surfaces of the band of the absorbent material; (c) at least partially covering the first and second surfaces of the web of absorbent material with the cover to form a mixed web having longitudinal side margins; (d) folding the mixed web at least once with the folds defining fold lines that are arranged around the longitudinal centerline of the web of absorbent material; and (e) autogenously joining a portion of the cover covering the first surface of the web of absorbent material to a portion of the cover that covers an opposite portion of the second surface of the web of absorbent material. In particularly preferred versions of the method of the present invention, the web of absorbent material comprises an absorbent foam material. The absorbent foam material preferably contains a high internal phase (or "HIPE") emulsion foam. The strip of absorbent foam material is preferably formed into a plurality of foam particles. In a preferred embodiment, this occurs between step (c) of at least partially covering the first and second surfaces of the web of absorbent material with the cover to form a mixed web, and step (d) of doubling the mixed web at least once. Step (d) for bending the mixed band at least once may further comprise: (i) folding the longitudinal side margins of the mixed band inward toward the longitudinal centerline around a first group of longitudinally oriented fold lines for forming a bent structure with a C shape; and then (ii) folding the mixed web inward about the longitudinal centerline, such that the longitudinal side margins of the bent mixed band are adjacent to each other. The tube of absorbent material attached and configured is attached to a base pad to form a composite sanitary napkin. In some embodiments, the ends of the tube of absorbent material are extended before the tube of absorbent material is attached to the base pad to provide the tube with a more pronounced profile shape. Numerous alternative embodiments and aspects for the absorbent article are included within the scope of the present invention. Also disclosed is a method for individually packing a three-dimensionally shaped absorbent article.

BRIEF DESCRIPTION OF THE DRAWINGS Although the specification concludes with the claims particularly pointing and indistinctly claiming the subject matter which is considered to be part of the present invention, it is believed that the invention will be better understood from the following description which is taken together with the drawings annexes, in which: Figure 1 is a perspective view of a composite sanitary napkin having a tube of absorbent material on its side facing the body, which is provided with a three-dimensional shape. Figure 2 is a schematic cross-sectional view of the composite sanitary napkin shown in Figure 1, taken along lines 2-2. Figure 3 is a perspective view of a composite sanitary napkin having a tube of absorbent material on its body facing side, wherein the tube of absorbent material is shorter than the base pad. Figure 4 is a schematic side view of a composite sanitary towel embodiment, which shows the tube profile of absorbent material. Figure 5 is a schematic side view of an alternative embodiment of the composite sanitary napkin which has a tube of profiled absorbent material, so that the highest caliber central lobe is located mainly over the central region of the base pad and the extreme rear region. Figure 6 is a schematic side view of an alternative embodiment of the composite sanitary napkin, which has a tube of shaped absorbent material, so that the central lobe of the highest caliber is located mainly over the central region of the base pad . Figure 7 is a perspective view of a composite sanitary napkin having an absorbent material on its side facing the body, the tube of absorbent material having an alternative three-dimensional configuration. Figure 8 is a schematic cross-sectional view taken through a part of a user's body showing how a sanitary pad composed of the prior art can be adjusted relative to the space between the user's lips.

Figure 8A is a schematic cross-sectional view taken through a part of the user's body showing an example of how the tube of three-dimensional absorbent material can be adjusted relative to the space between the user lips. Figure 8B is a schematic cross-section taken through a part of the user's body showing another example of how the tube of three-dimensional absorbent material can be adjusted relative to the space between the user's lips. Figure 9 is a schematic side view of a composite sanitary napkin such as that shown in Figure 1, which shows how the joints can provide flexion points around which the sanitary napkin can be folded three times to provide a sanitary napkin packed. Figure 10 is a schematic cross-sectional view similar to that of Figure 2, showing only the tube of absorbent material, showing how the triple fold preferably compresses the central lobe of the tube. Figure 11 shows the undesirable tendency for the central lobe which is displaced laterally relative to the longitudinal centerline of the composite sanitary napkin. Figure 12 is a schematic view of an alternative embodiment of a foam absorbent material in its folded configuration, which in this embodiment comprises a sheet having a central region comprising a soft foam, with large cells and external regions comprising a foam that is firmer, and that has smaller cells.

Figure 13 shows an embodiment wherein a foam absorbent material has particles or fibers of polymeric gelling agents in the form of a layer on the underside of a portion of the foam. Figure 14 is a cross-sectional view of a sheet comprising a strip of absorbent foam material between a pair of containment bands, wherein the portions of the foam absorbent material are scored and another portion is left in its original condition. Figure 15 shows another variation of a band of absorbent material, which provides a longitudinal center region with grooves oriented in the transverse direction and longitudinal side regions with grooves oriented in the longitudinal direction. Figure 16 shows a band of material having circ potions therein that have been formed into a partice material, and portions that have not been formed, wherein the regions are arranged in a pattern so that the unformed potions will form a plurality of spring-like structures when the band is bent. Figure 17 shows the web of material in Figure 16 after it has been bent longitudinally at various places to provide a tube type structure with spring-like structures on its sides. Figure 18 shows a web of material having portions in particles formed therein, which has been folded similarly to the web of the material shown in Figure 17, but the partice portions are formed in a different configuration to form a structure of type of armor. Figure 19 shows an embodiment in which the composite band is bent, so that the longitudinal side margins thereof do not extend beyond the central fold forming the central lobe. Figure 20 shows an embodiment wherein the composite band is bent in an alternative configuration to provide a pair of flexible lateral extensions extending from the central lobe. Figure 21 is a cross-sectional view of the body of a user encircling and including the labia majora and the labia minora of the user, showing how a tube of absorbent material can move to the side when the user squat. Figure 22 is a cross-sectional view of the same region of the user's body shown in Figure 21, which shows how a tube of absorbent material with flexible extensions can be adjusted when the user squat. Figure 23 is a schematic cross-sectional view of an alternative embodiment of the sanitary napkin having a tube of absorbent material comprising a plurality of lobes. Figure 24 shows an embodiment wherein the tube of absorbent material is integrated into the base pad. Figure 25 shows a variation of the embodiment shown in Figure 24, wherein the mixed web is bent in an alternative manner, so that some layers of material are inserted into the base pad. Figure 16 is a plan view of an alternative embodiment of a sanitary composite pad, wherein the absorbent material that is bent to form the tube of absorbent material also forms the absorbent core of the base pad. Figure 17 is a cross-sectional view of the sanitary napkin shown in Figure 26 taken along the line 27-27 of Figure 26. Figure 28 is a perspective view of the absorbent material folded into the sanitary napkin shown in Figures 28 and 27. Figure 29 is a cross-sectional view of another alternative embodiment of a sanitary napkin comprised of a folded absorbent material. Figure 30 is a cross-sectional view of another alternative embodiment of a composite sanitary napkin, wherein the absorbent material within the tube of absorbent material comprises a superior fluff material, which is folded into an inverted V-shaped transverse configuration . Figure 31 Figure 31 is a cross-sectional view of another alternative embodiment of a composite sanitary napkin, wherein the absorbent material within the tube of absorbent material comprises a superior fluff material, which is folded into a transverse configuration of three. lobes.

Figure 32 is a simplified schematic perspective view of a composite sanitary napkin, wherein the height of the tube of absorbent material varies along the length of the tube of absorbent material. Figure 33 is a plan view of a mixed web of absorbent material that is mechanically tensioned, so that it is formed as an hourglass-shaped configuration. Figure 34 is a plan view of the composite web of the absorbent material shown in Figure 33 after the mixed web has been joined inwardly and secured, so that a mound is formed longitudinally oriented down the center of the web mixed Figure 35 is a cross-sectional view of the composite web of absorbent material shown in Figure 34, taken along line 35-35 of Figure 34. Figure 36 is a schematic side view of a composite sanitary towel , wherein the ends of the tube of the absorbent material are attached to the base pad, and the portion of the tube between its ends is not attached to the base pad. Figure 37 is a schematic side view of a composite sanitary napkin wherein one end of the tube of absorbent material is permanently attached to the base pad, and the other end is releasably attached to the base pad. Figure 38 is a schematic side view of a composite sanitary napkin where both ends of the tube of absorbent material are releasably attached to the base pad.

Figure 39 is a schematic plan view of a sanitary napkin suitable for use as the base pad of a composite sanitary napkin or as an independent sanitary napkin having a depression therein that can be used by a user to insert one or more of their fingers, or their portions in order to assist in the desired placement of the tube of absorbent material or a portion between the lips of the sanitary napkin. Figure 40 is a schematic side view of the sanitary napkin shown in Figure 39 showing how a user can insert one or more of his fingers, or portions thereof, in order to assist in the desired placement of the tube of material absorbent or a portion between lips of the sanitary napkin. Figure 41 is a schematic side view of an alternative embodiment of a composite sanitary napkin, which has an adjustment assist mechanism in the form of a removable strip passing through the tube of absorbent material. Figure 42 is a schematic cross-sectional view of the absorbent material tube of the composite sanitary napkin shown in Figure 1, taken along line 42-42 of Figure 41. Figure 43 is a perspective view of a mixed web of material that will be configured to an absorbent tube having a three-dimensional shape for use as part of the sanitary napkin shown in Figure 1. Figure 44 is a perspective view of an apparatus used to form the absorbent material in the web mixed shown in Figure 43 to a particulate material. Figure 45 is a partially fragmented perspective view of the mixed web shown in Figure 43 after it has been fed through the apparatus shown in Figure 44. Figure 46 is a perspective view of the mixed web shown in Figure 43 after the side margins have been folded in a first fold operation. Figure 47 is a simplified schematic perspective view of the mixed web shown in Figure 43 after it has been folded in a second fold operation. Figure 48 is a perspective view of one embodiment of the method of the present invention, which is used to make a stock of absorbent material. Figure 49 is a simplified schematic perspective view of the mixed band shown in Figure 28 after that it has been formed by joining its portions together. Figure 50 is a simplified cross-sectional view of the web shown in Figure 49 taken through one of the bonding sites along line 50-50 of Figure 49. Figure 51 is a plan view simplified of a sanitary napkin having a hillock formed on its side facing the body through ultrasonic joints that are fused to thermoplastic fibers in the absorbent material. Figure 52 is a cross-sectional view of the sanitary napkin shown in Figure 51, taken along line 52-52 of Figure 51.

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an absorbent article comprising a tube of absorbent material three-dimensionally configured or formed and to a method for making the same. In a preferred embodiment, the absorbent article comprises a sanitary composite pad, and the tube of absorbent material provides the sanitary pad composed of the shape conforming to the desired body. 1. Total Characteristics of the Sanitary Towel The term "sanitary towel", as used herein, refers to an article that is used by women, adjacent to the pudendal region that is intended to absorb and contain the various exudates that are discharged of the body (for example, blood, menstruation and urine). The term "composite sanitary napkin", as used herein, refers to a sanitary napkin composed of several separate constituents attached to one another to form a unitary structure. Figures 1 and 2 show a preferred embodiment of a sanitary napkin 20 according to the present invention. The composite sanitary napkin 20 comprises a primary menstrual pad (the tube of absorbent material), which is attached to a panty-protector (or "base pad"). The sanitary napkin 20 comprises a tube of absorbent material 22 longitudinally oriented having a three-dimensionally formed structure that is attached to one of the surfaces of the base pad 24. The sanitary napkin 20 and the base pad 24 each have a surface that looks at the body and a surface that looks at the garment. The surface facing the body or "body surface" of the sanitary napkin is designated 20A and the sanding surface of the sanitary napkin is designated 20B. The body surface of the base pad 24 is designated 24A, and the garment surface is designated 24B. The sanitary napkin 20 is shown in Figure 1 seen from its body surface 20A. The body surface 20A is intended to be intended to be adjacent to the body of the user. The garment surface 20B is intended to be placed adjacent to the wearer's underwear when the sanitary napkin 20 is worn. The sanitary napkin 20 has two centerlines, a main longitudinal centerline L and a main transverse centerline T. The term "longitudinal", as used herein, refers to a line, axis or direction in the plane of the sanitary napkin 20 which is generally aligned with (e.g., approximately parallel to) a vertical plane that divides a user standing in left and right body halves when the sanitary napkin 20 is worn. The terms "transverse" or "lateral" used herein, are interchangeable, and refer to a line, axis or direction that lies within the plane of the sanitary napkin 20 which is generally perpendicular to the longitudinal direction. The tube of absorbent material 22 has two centerlines, a longitudinal center line L < And a transverse centerline T ^ The tube of absorbent material 22 is preferably attached to the base pad 24 so that the longitudinal centerline ^ of the tube of absorbent material 22 is aligned with the main longitudinal centerline of the sanitary napkin 20 The transverse centerline T of the absorbent material tube 22 can also be aligned with the main transverse centerline T ^ of the sanitary napkin 20 as shown in Figure 1. However, in other embodiments, the transverse centerline T of the Absorbent material tube 22 can be deflected either forward or backward of the main transverse center line T. The base pad 24 (and sanitary napkin 20) has a first end (or front) region 28, a second end region (or rear) 20, and a central region 32 positioned between the first and second end regions. The end regions 28 and 30 extend outwardly in the longitudinal direction from the edges of the central region 32 to about 1/8 to about 1/3., or more, of the length of the main body portion. The term "main body portion" refers to the portion of the sanitary napkin exclusive of any laterally extended fin which optionally may be provided thereon. (In the embodiment shown in Figure 1, the main body portion comprises the base pad 24 and the tube of absorbent material 22). A detailed description of the characteristics of a central region and two end regions for a sanitary napkin is contained in the patent of E. U. A. 4,690,680, issued to Higgins on the 1st. September 1987. The characteristics of the sanitary napkin 20 can also be described in terms of a Cartesian coordinate system. For the purpose of this description, the X axis runs along the main longitudinal centerline L of the sanitary napkin 20. The Y axis runs along the main transverse center line, T, of the sanitary napkin 20. The XY plane is a plane generally parallel to the faces of the base pad 24. The Z direction is perpendicular to the XY plane.

A. Tube of Absorbent Material Three-dimensionally Formed or Configured The three-dimensional aspects of the tube of absorbent material may include, but are not limited to the following characteristics, which are described in detail below: the fact that a portion of the tube of absorbent material be segregated from another portion or portions thereof; the tube profile of absorbent material; the lobes of the tube of absorbent material; and the indentations or tufted regions formed in the tube of absorbent material. The tube of absorbent material 22 can have a number of different three-dimensional shapes. In the preferred embodiment shown in Figure 2, the tube of absorbent material 22 can be described having an inverted "T" -shaped cross section, or more specifically, a "three-lobed" cross-sectional configuration in the central region 32. of the sanitary napkin 20. As shown in Figure 2, the three-lobed tube comprises a central lobe 34 and two external lobes 36 and 38. The tube of absorbent material 22 is attached to the body surface 24A of the base pad 24, as shown in Figure 2, central lobe 34 is preferably symmetrically disposed about the main longitudinal center line L of sanitary napkin 20. Central lobe 34 preferably has a larger caliper than outer lobes 36 and 38. The outer lobes of preference are also symmetrically disposed about the main longitudinal center line L of the sanitary napkin 20 and have the Like the others among themselves. The central lobe 34 is preferably layers to obtain a conformable, comfortable lip fit (i.e., a fit in the space between the major and minor lips of a woman). The central lobe 34 and the outer lobes 36 and 38 can be of any suitable size that allows this to occur. The central lobe 34 preferably has a caliber (or Z direction height (first gauge)) in the range of between about 7 mm to about 25 mm, measured from the body facing surface 34A of the base pad 24. The lobes external 36 and 38 preferably have a gauge (second gauge) in the scale of between about 2 mm to about 10 mm, measured from the surface facing the body of the base pad. The previous calibers of the central lobe 34 and the outer lobes 36 and 38 are measured under a confining pressure of 350 Pa. The base pad 24 preferably defines a third gauge of the entire sanitary napkin 20, and the third gauge preferably is smaller than the first and second calibers. The composite sanitary napkin of the present invention differs from the prior art sanitary napkins having tubes of absorbent material with a circular or oval cross-sectional configuration. In the case that some users of the composite sanitary napkin of the present invention, substantially all of the tube of absorbent material can be fined within the space between lips (along at least one section along the length of the tube) without there being any action on the user's part. Figure 8 is a schematic cross-section taken through the important part of the user's body showing how a sanitary towel composed of the prior art having a tube with a cross-section or oval can be adjusted relative to the space between the user's lips . In Figure 8, the user's legs are designated with the double reference letter W, the labia majora are designated with the reference letter M, and for the purposes of this specification only, the distant surfaces of the labia majora are designated with the reference letter D. In some embodiments, tubes having circular or oval cross-sectional configurations can achieve a degree of adjustment between the lips.

As shown in Figure 8A, the fit between the lips that the tube of absorbent material 22 three-dimensionally formed of the sanitary napkin 20 of the present invention is capable of achieving, is many times greater than that previously obtainable with sanitary napkins having water tubes. transverse circular or oval configurations. The tube of absorbent material 22 of the sanitary napkin 20 of the present invention penetrates much more into the space between the lips and achieves much better compliance with this region of the user's body. The tube of absorbent material 22 is also preferably highly elastic under wet and dry conditions, so that it dynamically adjusts and conforms to changes in the shape of the lip space and does not collapse when subjected to pressure and / or when it is moistened by the exudates of the body. The cross section of three lobes is advantages since the outer lobes 36 and 38 provide additional absorbent material to supplement the absorbent material provided by the central lobe 34 that is formed between the lips. The outer lobes 36 and 38 may be substantially in the same relationship with the central lobe 34 and lie outside the space between the user's lips as shown in Figure 8A and intercept the exudates from the body as they leave the user's body. The outer lobes 36 and 38 provide an additional surface area adjacent to the distal surfaces D, of the labia majora M, to intercept the exudates discarded from the wearer's body. At. In case of some users, however, as shown in Figure 8B, the outer lobes 36 and 38 can converge and form a narrower structure where they also fit at least partially between the lips. As shown in Figure 8B, in some users, this narrower structure is able to fit substantially completely between the lips, with the outer lobes also fitting between the lips. Although this is not mandatory, the tube of absorbent material 22 preferably intercepts most or all of the exudates discarded by the body, so that the base pad 24 remains clean and dry. The tube of absorbent material 22 in the embodiment shown in Figure 2 is preferably formed from three components. These comprise a topsheet 40, an absorbent material 42 and a containment band 44. The topsheet 40 can be manufactured from a wide variety of materials, such as woven and non-woven materials; polymeric materials such as thermoplastic films with formed openings, plastic films with openings or without openings, and hydroformed thermoplastic films; porous foams, cross-linked foams; crosslinked thermoplastic films; and thermoplastic canvases. Suitable woven and nonwoven materials may be composed of natural fibers (eg, wood or cotton fibers) synthetic fibers (e.g. polymeric fibers such as polyester, polypropylene or polyphenylene fibers); Two-component fibers (ie, fibers having a core of a material that is encased in a sheath made of another material), or a combination of natural and synthetic fibers. In a preferred embodiment, the topsheet 40 comprises a film formed with openings. The topsheet 40 may comprise a formed film such as that described in U.S. Patent 4,637,819, issued to Ouellette, et al., Or U.S. Patent Application Serial No. 08 / 442,935 entitled "Fluid Transport Webs Exhibiting Surface Energy Gradients". Fluid Transport Bands Showing Surface Energy Gradients), filed in the name of Ouellette et al., On May 31, 1995 (PCT publication WO 96/00548, published January 11, 1996). An especially preferred apertured formed film is described in U.S. Patent 4,342,314 issued to Radel et al. On August 3, 1982 and U.S. Patent 4,463,045, issued to Ahr on July 31, 1984, which sell sanitary napkins at the name of Procter &; Gamble Company of Cincinnati, Ohio as the top sheet "DRI-WEAVE". Preferably, this upper sheet material is provided with additional softness and flexibility by forming a pattern in the upper sheet material while being fed through a nozzle between matching rollers together with a preferred process for forming the absorbent material in a plurality of particles ( described later). It has been found that this process greatly changes the appearance and feel of the surface of the preferred apertured film upper sheet material, so that at present it is no longer recognized as the same film with apertures, but rather appears to be a material type "fabric", "gauze type", or "cotton" type. The absorbent material 42 in the tube of absorbent material 22 may be any absorbent material that is capable of absorbing or retaining liquids (e.g., menstruation and / or urine). The absorbent material 44 in the tube of absorbent material 22 can be a wide variety of liquid absorbent materials commonly used in sanitary napkins and other absorbent articles such as pulp of crushed wood, which is generally referred to as air felt. Examples of other suitable absorbent materials include curled cellulose wadding; meltblown polymers including co-form; chemically hardened, modified or cross-linked cellulosic fibers; synthetic fibers such as crimped polyester fibers; peat; tissue including tissue strips and fabric laminates; absorbent foams; absorbent sponges; superabsorbent polymers; absorbent gelling materials; and any equivalent materials or combinations of materials, or mixtures thereof. The absorbent material may also partially comprise a less absorbent or non-absorbent material, such as polyurethane foam, which when combined with the absorbent material, (such as absorbent gelling materials), may be formed into suitable absorbent structures. Preferred absorbent materials are those in the above list which are wet and dry elastics and / or can be formed into an elastic structure. Particularly preferred absorbent materials can also be comminuted to particles in the preferred process to make the tube of absorbent material described below. The absorbent material in the tube of absorbent material 22 preferably comprises an absorbent foam, preferably an elastic absorbent foam. Some particularly preferred absorbent foam materials are made from high internal phase emulsions, and are known as "HIPE" foams. Suitable HIPE absorbent foams are described in U.S. Patent No. 5,260,345 issued to DesMarais et al. On November 9, 1993; U.S. Patent No. 5,268,224 issued to DesMarais et al. on December 7, 1993; U.S. Patent No. 5,387,207 issued to Dyer et al. on February 7, 1995; U.S. Patent No. 5,550,167 issued to DesMarais on August 27, 1996; U.S. Patent No. 5,563,179 issued to Stone et al. on October 8, 1996; U.S. Patent No. 5,650,222 issued to Des Marais on July 22, 1997; and patent application of E. U. A. series No. 08 / 542,497 filed on October 13, 1995 by Dyer et al. (Case P &G 5546R). These patents may be referred to herein as the patents for "absorbent foam material." Said absorbent foam materials are particularly preferred, since they can be provided with good resistance to compression and elasticity after compression. The absorbent foam materials described in these different patents have properties that allow them to acquire and / or store various body exudates. They can also be provided with the ability to absorb particular types of exudates from the body (for example, menstruation, bowel movements, and / or urine). Such materials may have a low tensile strength and / or low structural integrity, which makes them suitable for shredding them into particles. In particularly preferred embodiments, the absorbent foam material comprises a plurality of particles 48 of absorbent foam. The absorbent foam particles 48 are best seen in Figure 50, which is a view of the tube of absorbent material 22 in an inverted condition before being joined to the base pad 24. The particles may be in any suitable form. They can have regular or irregular shapes. Examples of particles having regular shapes are particles in the form of cubes, rectangular three-dimensional particles, prisms, or other parallelepipeds. All the particles can be of the same general size and / or shape, or they can be of varying sizes and / or shapes. In a preferred embodiment, the particles of the absorbent foam material 48 are generally in the parallelepiped configuration. When the absorbent foam particles 48 are described as being "generally" in a particular configuration, it is understood that they do not need to be exactly in the specified configuration, and that all the particles 48 need not be exactly in the specified configuration. It is sufficient if some of the particles 48 are approximately in the specified form, so that they can be recognized as having said shape. The particles 48 of the absorbent foam material can be of any suitable size. The particles preferably have a larger dimension having a nominal size, ie, preferably between about 1.0 mm and about 25.4 mm, and most preferably between about 2 mm and about 16 mm. However, particles as small as 0.5 mm and smaller, and particles larger than approximately 25.4 mm are also contemplated. Particles having a nominal size of about 1.0 mm or greater are those that are generally retained on the surface of the US standard No. 18 mesh screen. Particles having a nominal size of less than about 25.4 mm are those that generally pass through Through a US standard 25.4 mm screen In a preferred embodiment, the particles 48 are rectangular prisms or parallelepipeds that are approximately 1.5 mm x 1.5 mm x 2 mm. The particles of absorbent foam material 48 may all be of a relatively uniform size, or may be of varying particle sizes. In the preferred embodiment shown, they are of a relatively uniform particle size. The use of particles of absorbent material provides a number of advantages. The particles of the absorbent foam material 48 provide the tube of absorbent material 22 with an elastic "beanbag" type structure that allows a better conformation to the shape of this region of the user's body than does the bands or sheets of absorbent materials. The use of foam particles is also believed to make the tube of absorbent material 22 softer and more comfortable for the user. However, it should be understood that by making the tube of absorbent material 22 partially or completely of the absorbent material comprising sheets or strips of absorbent material such as absorbent foam, it is also within the scope of the present invention. The absorbent foam material particles 48 are preferably held in place within the containment web 44. The containment web 44 can be any suitable material that is capable of containing the particles of absorbent foam material 48. For the preferred embodiment As described herein, the containment web 44 should also be capable of being used as a carrier web in the process to form the particulate absorbent foam material., as described in detail later. The containment band 44 can be made from a wide variety of materials, such as woven and non-woven materials; polymeric materials such as thermoplastic foams formed with openings, plastic films with openings or without openings, and hydroformed thermoplastic films; porous foams, cross-linked foams; cross-linked thermoplastic foams; and thermoplastic canvases. Particularly preferred materials for use as the containment band are described in greater detail together with the method for making the tube of absorbent material 22. In a preferred embodiment, as will be discussed in detail below, the containment band 44 comprises a band. of material, such as a nonwoven web that is wrapped around the particles of the foam absorbent material 48 to form a mixed web 50. In particularly preferred embodiments, the composite web 50 is then bent (preferably longitudinally) at least in one place to provide the tube of absorbent material 22 with a different three-dimensional shape. (The fold of the mixed band 50 provides greater flexibility in the number of three-dimensionally formed structures in which the mixed band 50 can be formed). The containment band 44 provides a number of advantages. A major advantage is that it contains the particles 48 within the limits of the containment band 44, so that the mixed band 50 can be bent or otherwise manipulated. Because of this, the particles 48 will remain in the same ratio relative to the adjacent portions of the containment band 44, instead of falling into a loose mass of particles at the lowest point of the bent mixed band 50. The components of the tube of absorbent material 22 can be joined together, if desired. Alternatively, one or more of these components need not be attached to the adjacent component or components. In a preferred embodiment, the topsheet 40 and the containment band 44 are joined together to form a mixed topsheet, and the mixed topsheet is attached to the absorbent material. If these components are joined, they can be joined together in any suitable manner, such as by means of adhesives. Preferably, they are bonded through a spiral pattern of adhesives. An adhesive for this purpose is a hydrophilic adhesive known as the Findley # 4111 adhesive obtained from Findley Adhesives of Wauwatosa, Wl. Preferably, as described in detail in the section of this specification which relates to the method for making the tube configured of absorbent material, these components are also integrated together by passing them through a nozzle between one or more pairs of matching rollers together with a preferred process for forming an absorbent material 42 in a plurality of particles. The mixed band 50 can be bent in any suitable structure. The mixed band 50 can be bent (and then bonded) to form structures having a wide variety of cross-sectional configurations. The cross-sectional configuration of the tube of absorbent material 22 can be uniform along the length of the tube or can vary along the length of the tube of absorbent material 22. The mixed band 50 can be bent to provide a structure that it is profiled (or contoured) along its length, profiled in width (in the transverse direction) and / or profiled in height. By providing different transverse configurations along the length of the sanitary napkin, this can be used to provide the absorbent material tube 22 with an optimum shape for body shaping at each location along its length. To form the preferred three-lobed embodiment shown in Figure 2, the mixed web 50 is folded into three places around longitudinally oriented doubles lines. The longitudinal side margins of the mixed band bend inward towards the center line longitudinal of the mixed band 50. The mixed band 50 then bends inward again around its longitudinal center line. The fold lines form the mixed band 50 in an inverted U-shaped configuration on its upper surface and two U-shaped portions along its lower surface. One of the fold lines F4 (one that is formed at the end) forms a ridge on the upper surface of the tube of absorbent material. The U-shaped portions along the bottom surface are preferably bent inwards, so that the other two fold lines, F2 and F3, form the lateral sides of the tube of absorbent material. The bending process is described in detail below along with the method for making the tube of absorbent material 22. It should be understood that it is not necessary that these bending lines form sharp bends in the mixed band 50, rather, the lines of fold preferably imparts gradual push-ups in the mixed band 50. The preferred process for forming the absorbent foam into particulate material (described in detail below) is advantageous as it provides the mixed band 50 with additional flexibility to assist the mixed band. to bend in this way. But for this additional flexibility, the absorbent foam material 42 can fracture at sites that are undesirable when the mixed web 50 is folded. In addition, if not for this additional flexibility, the topsheet 40, the containment band 44 and / or the combined structure 52 comprising the topsheet 40, the absorbent material 42 and the containment band 44, could be under excessive stresses, the which could be difficult to bend the combined structure to the desired configuration. The tube of absorbent material 22 three dimensionally formed preferably has at least one, and preferably three, autogenous fusion joints 54 formed therethrough. A compressed (or "tufted") region 56 surrounds the joints 54. The joints 54 secure the combined bent structure 52 in its bent configuration. The portions 58 of the combined structure 52 that are not held together by the joints 54 can be unfolded (or bent, if desired) and oriented in other directions. The joints 54 in this manner can be considered as different segregation portions of the tube of absorbent material 22 to assist in the formation of a structure with a different three-dimensional shape. The joints 54 preferably segregate a first portion of the tube of absorbent material 22, and in the embodiment shown in Figures 1 and 2, create a raised tubular rim 60. The raised tubular rim 60 creates the central lobe of the transverse configuration. In a particularly preferred embodiment, the joints 54 are located in the portion of the tube of absorbent material 22 that will lie in the central region 32 of the sanitary napkin 20. The portions 58 of the tube of absorbent material 22 that are not held together by the joints 54 (the second portion of the tube of absorbent material 22) are bent away from each other at an angle of about 180 relative to each other to form the outer lobes 36 and 38. When the tube of absorbent material is viewed from the outside 22 three-dimensionally formed, as in Figure 1, the second portion of the tube of absorbent material 22 has a generally oval transverse configuration. The oval shape has a pair of longer sides and a pair of shorter curved sides, and one of the longer sides is positioned adjacent the body facing side 24A of the base pad 24. In the preferred embodiment shown in FIG. Figure 1, portions 62 and 64 of the tube of absorbent material 22 that will lie in the end regions 28 and 30 of the sanitary napkin are preferably at least slightly flattened and bonded to the base pad 24. The tube of absorbent material 22 it can also, as will be described in detail below, be attached to the base pad 24 between its ends 62 and 64. As shown in Figures 1 and 4, the tube of absorbent material 22 can be profiled from the front end region 28 of the sanitary napkin 20 towards the rear end region 30 of the sanitary napkin. More specifically, the tube of absorbent material 22 has its highest caliper in the center of the sanitary napkin along the transverse center line, T, and tapers to a smaller gauge at the ends of the sanitary napkin. The joints 54 form the central lobe 34, where they are present, but do not provide the tube of absorbent material 22 with a central lobe where they are absent.

The bonding patterns can be varied to create a tube of absorbent material with increased gauge along all or any portion of the length of the sanitary napkin 20. Further variations are shown in Figures 5 and 6. For example, the The union can be such that the increased gauge is confined to the central region 32 of the sanitary napkin 20 as shown in Figure 6. Alternatively, the bonding pattern can be used to provide an increased gauge in the end regions, or as shown in Figure 5, in a portion of the central region and a portion of the end regions.

B. The Composite Sanitary Towel Base Pad The sanitary composite pad 20, as noted above, comprises a panty-pctor (or "base pad") 24 and the tube of absorbent material (or "primary menstrual pad") 22, which is placed on top of the base pad 24 and is attached thereto at least at the ends of the tube of absorbent material 22. The base pad 24 can be provided in any suitable configuration and can be constructed to from any suitable component. The base pad 24 preferably has generally flat surfaces and is relatively thin. The base pad 24 preferably has a gauge less than or equal to about 7 mm, preferably less than or equal to about 5 mm and most preferably less than or equal to about 3 mm. The base pad 24 preferably comprises an ultra thin sanitary napkin. Sanitary pads suitable for use as the base pad 24 include ALWAYS ULTRA sanitary napkins sold by The Procter & Gamble Company of Cincinnati, Ohio. The base pad 24 preferably comprises a liquid pervious top sheet 70, a liquid impermeable back sheet 72 bonded to the top sheet, and an absorbent core 74 positioned between the top sheet 70 and the back sheet 72. The backing pad base 24 may also comprise an optional secondary top sheet 76 which is positioned between the top sheet 70 and the absorbent core 74, or a part of a mixed top sheet may be made. The components of the base pad 24 may be selected from the same types of materials used as the topsheet, absorbent material and tube retaining band of absorbent material 22. Other materials suitable for the base pad components 24 , and the descriptions of the assembly thereof, are contained in US Patents 4,950,264, 5,009,653, 5,460,623 and 5,569,231. In a particularly preferred embodiment, the base pad 24 comprises a variation of said ALWAYS ULTRA sanitary napkin. This base pad 24 preferably comprises a polyethylene film backing sheet 72, an absorbent core 24 comprising a sheet of tissue or tissue paper with superabsorbent hydrogel-forming material particles therebetween, and a fabric 76 and a film with openings DRI-WEAVE 70 covering absorbent core 74. Suitable fabrics are manufactured by Merfin Hygienic Products, Ltd. of Delta, British Columbia, Canada. The fabric 76 covering the absorbent core 74 is preferably bonded to the absorbent core 74 through a spiral pattern of adhesive. Preferably, the components of the base pad 24 are free of any fusion bond in this embodiment for greater flexibility. The increased flexibility allows the composite sanitary napkin, and particularly the tube of absorbent material 22 thereon to more readily assume the desired conformation to the body configurations shown in Figures 8A and 8B. In this particularly preferred embodiment, the base pad 24 also comprises fins that extend laterally outward from their longitudinal side edges. Suitable fins are described in detail below. C. Relationship Between the Three-Dimensional Absorbent Shaped Material Tube and the Base Pad The absorbent material tube 22 may be of any suitable length relative to the base pad 24. The tube of absorbent material 22 may be as long as the pad of base 24, as shown in Figure 1. In other embodiments, as shown in Figure 3, the tube of absorbent material 22 may be shorter than the base pad 24. In this last embodiment, as shown in Figure 3 , it may be desirable to provide the absorbent material tube 22 with an anti-penetration end seal 80 at both ends to prevent fluids from penetrating away from the ends of the tube of absorbent material 22. The tube of absorbent material 22 may cover any appropriate portion of the base pad 24. The tube of absorbent material 22 may cover the front end region 28 of the base pad, the rear end region 30 of the base pad, the central region 32 or any portion or portions thereof. In other embodiments, the larger-gauge central lobe (or height) 34 of the tube of absorbent material 22 can be configured to cover any of these regions of the base pad 24 instead of placing the entire tube of absorbent material 22 over the regions selected from the base pad 24. Figures 4 to 6 show some non-limiting configurations of the tube of absorbent material 22 from the side. The central gauge lobe 34 of the tube of absorbent material described herein is not limited to any particular length. In a version of the embodiment shown in Figure 6, the length may be in the range of about 50 mm to about 100 mm. Said embodiment may be useful if it is desired to provide the sanitary napkin with a tube of absorbent material 22, wherein the central lobe 34 is sufficiently short in length that it is completely fixed between the lips. As discussed above, the tube of absorbent material 22 is attached to the base pad 24. The term "attached", as used herein, encompasses configurations wherein one element is directly secured to another element by fixing the element directly to the another element; configurations wherein the element is indirectly secured to the other element by fixing the element to intermediate members, which in turn are fixed to the other element; and configurations where one element is integral with another element, that is, one element is essentially part of the other element. The tube of absorbent material 22 can be attached to the base pad 24 in any suitable manner. The tube of absorbent material 22 in the embodiment of the composite sanitary napkin shown in Figure 1, preferably has an upper sheet 40 which is longer than the rest of the components of the tube of absorbent material 22, so that there are extensions 158 of the upper sheet material at the ends of the tube of absorbent material 22. The attachment of the tube of absorbent material 22 to the base pad 24 is preferably achieved through fusion bonding of the extensions 158 of the sheet material at the ends of the sheet. tube to the base pad 24. In some preferred embodiments of said composite sanitary napkin, there may also be a bond to the base pad 24 between the ends of the tube of absorbent material 22 and the base pad 24. The tube of the towel Composite sanitary can be attached to the base pad between its ends through any suitable joining means, such as through adhesives . In other embodiments, the tube of absorbent material 22 can be handled in a different manner before it is attached to the base pad. For example, Figure 7 shows an embodiment wherein the portions 62 and 64 of the tube of absorbent material 22 that will already be in the end regions 28 and 30 of the sanitary napkin are extended or widened more dramatically. The absorbent material tube 22 of the composite sanitary napkin 20 shown in Figure 7 can be believed to have a "curved junction" plan view configuration. In this embodiment, the portion of the tube of absorbent material 22 that lies in the central region 32 of the sanitary napkin can only have a central lobe 34, or few or no recognizable outer lobes. The portions of the tube of absorbent material that lie in the end regions 28 and 30 of the sanitary napkin can be almost completely flattened, having only the outer lobes 36 and 38, and little or no recognizable central lobe. This is possible since the portions 62 and 64 of the tube of absorbent material 22 that will lie in the end regions 28 and 30 of the sanitary napkin are not held together by the joints 54. Further descriptions of the characteristics of composite sanitary napkins and shapes of Binding of composite sanitary napkin components (although they do not comprise the technology described herein) are found in the US patent of P & G 4,425,130 entitled "Compound Sanitary Napkin" (Compound Sanitary Towel) issued to DesMarais et al. On January 10, 1984, and in State Invention Register H1614 entitled "Body Fitting Compound Sanitary Napkin" (Composite Sanitary Towel) ), published in the name of Mayer et al. on November 5, 1996. The garment surface 20B of the sanitary napkin 20 may include, and preferably includes, fasteners for attaching the sanitary napkin to the wearer's underwear. Figure 2 shows the central pad fastener 20, which is adapted to secure the main body portion of the sanitary napkin to the crotch region of an undergarment. Any type of fastener known in the art, such as adhesive fasteners and mechanical fasteners can be used as the central pad fastener 90. The fasteners comprising adhesives have been found to work very well for this purpose, with the adhesives being sensitive to the Pressure.

D. Packaging and Use of the Composed Sanitary Towel The sanitary towels composed herein described are preferably individually packaged. In particularly preferred embodiments, the sanitary napkin 20 is individually packaged by bending the same in three parts around at least one, and preferably two transverse shafts together with a releasable wrapper 92 that is releasably attached to the central pad holder 90 (as shown in FIG. shown in Figure 9). A suitable releasable wrapper 92 for this purpose is described in U.S. Patent No. 4,556,146 issued to Swanson. A particularly preferred releasable wrapper comprises an adhesive fastening system such as that described in U.S. Patent No. 5,413,568 issued to Roach et al., And a seal disclosed in U.S. Patent No. 5,462,169 issued to Minton et al. The location of the joints 54 in the tube of absorbent material 22 is important in the process of three bends. The transverse axes are preferably located in regions adjacent to that include at least one of the fusion joints 54 of the tube of absorbent material 22. Preferably, as shown in Figure 9, the joints 54 that penetrate the tube of absorbent material 22 they are located in or inward of the transverse axes around which the sanitary pad 20 and the wrapper 94 will be folded. As shown in Figure 9, this aids in the process of three bends providing bending points around which the tube of absorbent material 22 will be folded in a controlled manner. This is particularly useful for bending relatively high gauge components such as the tube of absorbent material 22. The fold of the sanitary napkin 20 in such a manner also has the advantage of allowing the position of the central lobe 34 of the tube of absorbent material 22 to be controlled The three bends will involve applying pressure to compress the tube of absorbent material 22. This has the effect of flattening and centralizing the central lobe 34 of the tube of absorbent material 22 as shown in Figure 10. This provides the advantage of making one more article compact for packaging, and consequently, an individually packed absorbent article more compact. The compression also controls the location of the central lobe 34 and avoids the undesirable tendency for the central lobe 34 to be laterally displaced as shown in Figure 11. It should be understood that the packaging method described here by bending around the attachment points on The sides of an absorbent article is not limited to use with composite sanitary napkins. This method can be used with any three-dimensionally shaped absorbent article having a height defining longitudinal sides where one or more fusion junctions (or other indentations or teeth) are formed on the longitudinal sides to provide bending axes to bend the absorbent article. To use the sanitary napkin 20 as shown in Figure 1, the sanitary napkin and the wrap 92 are unfolded and the sanitary napkin 20 is removed from its package. The absorbent foam materials described above are especially preferred for use in the tube of absorbent material 22, since these materials are highly elastic and will not only provide the benefits described hereinbefore, but will also substantially impact all their uncompressed dimensions even after that the tube of absorbent material 22 has been highly compressed during packing and held in a compressed configuration prior to the time the package is opened by the consumer. Preferably, the tube of absorbent material 22 will recover more than or equal to about 50%, preferably about 60%, preferably about 70%, preferably about 80, and most preferably about of 90% of its uncompressed caliber. The sanitary napkin 20 is then placed in the crotch region of the wearer's panties and the central pad adhesive fastener 90 keeps the sanitary napkin 20 in place. The panties are then placed in the usual way. The sanitary napkin of the present invention provides advantages over conventional thick sanitary napkins. The sanitary napkin of the present invention provides a thickness only where it is necessary. The sides of the composite sanitary napkin are flexible and comfortable as an ultra thin sanitary napkin. By thickening the absorbent material in the central region of the sanitary napkin, additional protection and confidence will be provided to consumers if they are not comfortable with these aspects of current ultra-thin sanitary napkins. The tube of absorbent material 22 three-dimensionally formed provides the only advantage that it dynamically fits within the space between the lips of the user without any action on the part of the user. The composite sanitary napkin, in some modalities, it is possible to believe that it has a pad between the lips of self-adjustment. The preferred three-lobed cross-section of the tube of absorbent material 22 provides an additional surface area to intercept the body fluids as shown in Figure 8A, or form lobes that converge to be fixed between the lips as shown in Figure 8B . Both configurations contribute to maintaining the base pad 24 in a clean and dry condition. The provision of the absorbent material in the tube of absorbent material 22 in the form of particles allows the tube of absorbent material to conform to the shape of the user's body better than when the absorbent material is in the form of a sheet or band of material . The provision of the absorbent material in the tube of absorbent material 22 in the form of particles also makes the tube of absorbent material softer and more comfortable for the user. The provision of the joints 54 in the tube of absorbent material allows the tube of absorbent material to be formed in an optimal configuration to conform to the body. The joint, as discussed above, also helps to form the sanitary towel composed into a individually packaged, convenient article. The process for making the sanitary towel provides a number of additional benefits. These benefits are described in detail later.

E. Alternative Modalities and Characteristics Numerous embodiments of the sanitary napkin of the present invention are also possible. For example, in an alternative embodiment, the absorbent material in the tube of absorbent material 22 need not be formed into particulate material. That is, a solid piece of absorbent material can be used. However, this may reduce the ability of the tube of absorbent material 22 to conform to the wearer's body. In addition, the formation of fusion bonds through a solid absorbent material, such as an absorbent foam material will be more difficult particularly if it has a thickness of more than 4 mm. In other embodiments, the absorbent material within the tube of absorbent material 22 may be in configurations other than particles. For example, the absorbent material may be in the form of strands, strips, or strips of absorbent material. In any of the absorbent embodiments, or other materials, different materials may be used for the topsheet 40 on the portion of the tube of absorbent material 22 that fits between the lips (the "lip portion") of the tube of absorbent material 22 For example, this portion of the tube of absorbent material 22 may comprise nonwoven materials and the remainder of the topsheet 40 may comprise a film with openings. This can provide this portion with the tube of absorbent material with improved comfort. Alternatively, if the topsheet 40 comprises a nonwoven material, the lip portion of the topsheet 40 may comprise softer nonwovens than the rest of the topsheet. In addition, all or portions of tubes of absorbent material 22 may also comprise emollients or lubricants for improved comfort and / or easier insertion and removal. Suitable emollients are described in U.S. Patent 5,635,191 entitled "Diaper having A Lotioned Topsheet Containing A Polysiloxane Emollient" (Diaper Having a Top Slip with Lotion Containing a Polysiloxane Emollient) issued to Roe et al. On June 3, 1997, and U.S. Patent 5,643,588 entitled "Diaper Having a Lotioned Topsheet", issued to Roe et al. on the 1st. June 1997 In any of the above embodiments, or other embodiments, the material within the tube of absorbent material 22 may comprise a mixture of more than one type of HIPE foam described in the patents of absorbent foam material. Alternatively, the material within the tube of absorbent material 22 may comprise a mixture of the same basic type of HIPE foam, but which has particles with different properties, or a structure comprising portions with different properties. For example, Figure 12 shows an embodiment wherein the absorbent material 42 for the tube of absorbent material 22 comprises a sheet or band of absorbent foam that has been prepared and bent into the desired cross-sectional configuration. Foam sheet 42 shown in Figure 12 has a central region 1200, which comprises a soft foam, with large cells 1202 (shown schematically) for improved acquisition, particularly for the acquisition of solid material such as cellular waste. The central region 1200 will be in closer contact with the portion of the user's body that discards exudates from the body. The outer regions 1204 of the foam sheet (i.e., the regions extending to the longitudinal edges thereof) may comprise a foam that is firmer, and which has smaller cells 1206 to establish a capillary gradient to penetrate the liquids from the portions 1200 of the foam having the largest cells 1202. The firmer external regions 1204 also act to help keep the central lobe in a straight condition.

In other embodiments, the materials within the tube of absorbent material 22 may differ from the preferred absorbent foam material described above. For example, the materials within the tube of absorbent material 22 may comprise a mixture of absorbent and non-absorbent foams. Alternatively, thermally bondable materials or other elastic materials may be used in the tube of absorbent material 22. In addition, other types of absorbent materials (e.g., conventional absorbent materials such as wood pulp or other cellulose fibers, binder fibers, and or particles or fibers of polymeric gelling agents) can be added to the absorbent material in the tube of absorbent material 22. These types of absorbent materials can be mixed homogeneously, or laminated to the central or lower regions of the tube of absorbent material 22. For example, Figure 13 shows an embodiment wherein the absorbent material 42 for the tube of absorbent material 22 comprises a folded layer of absorbent foam material 1300. The layer of absorbent foam material has a polymeric gel-forming material in the form a layer on the underside of at least a portion of the layer of foam 1300. The polymeric gelling agent can be in the form of particles or fibers. In the embodiment shown in Figure 13, the polymeric gelling material is in the form of fibers of polymeric gelling material in a layer on the underside of a portion of the layer of absorbent foam material 1300. Figure 14 shows In other embodiments, the mixed web 50 used to form the tube of absorbent material 22 can be structurally modified to provide regions thereof with different properties. For example, Figure 14 shows the absorbent foam material 42 which is placed between two layers of containment web material 44 before bending the mixed web 50. The absorbent foam material 42 shown in Figure 14 has a central region 1400. and lateral regions 1402 laterally outwardly of the central region 1400. The central region 1400 is structurally unmodified, i.e., left in the form of a solid sheet. However, the side regions 1402 are structurally modified (such as grooving or forming particles). In any case the absorbent foam material 42 in the side regions 1402 will be divided into (or cut into) separate components. These separate components can be strips or particles and are represented by the reference number 1404. Figure 15 shows another example of said structure. Figure 15 shows a band of absorbent material 1510 having a region along its longitudinal center line (a "longitudinal center region") 1512 having a pattern of grooves formed therein, and regions laterally outward thereof. ("longitudinal side regions") 1514 and 1516 having a different pattern of grooves formed therein. Said absorbent material, which comprises part of a mixed absorbent structure, can be bent into a tube-like structure similar to that shown in the preceding Figures. As shown in Figure 15, the longitudinal center region 1512 may be provided with a plurality of transverse grooves 1518 (or transverse direction of the machine). The transverse slots 15 and 18 can be used to provide the bent tube with greater flexibility along its length than in the transverse direction. The transverse grooves 1518 form a plurality of transversely oriented strips of absorbent material in the longitudinal center region 1512. These strips provide the longitudinal center region 1512 with the ability to preferentially penetrate (or transport) liquids in the transverse direction. The liquids are preferably transported to the longitudinal side regions 1514 and 1516 to make full use of the web of the absorbent material. The longitudinal side regions 1514 and 1516 are preferably provided with longitudinally oriented slots 1520, continuous forming a plurality of longitudinally oriented strips of absorbent material. These strips provide the longitudinal side regions 1514 and 1516 with the ability to transport liquids in the longitudinal direction. The longitudinally oriented slots 1520 can also be used to avoid any undesirable tendency for liquids to flow transversely out of the tube of the absorbent material by establishing gaps that tend to prevent capillary transport from a strip to the adjacent strip.

Figures 16 to 18 show other examples of ways in which the mixed band can be structurally modified to provide regions with different properties. These modifications can be used to easily create structures that trend principles of mechanical and / or civil engineering designs. Such structures include, but are not limited to, network structures of crystalline structure, wireframe mesh type structures, trusses, I-beams, A-beams or lifting spring. Said structures are useful for adding various characteristics such as stability, flexibility and elasticity to the tube of absorbent material 22. Figure 16 shows a web of material, such as a strip of absorbent material 1600 having portions or areas 1602 therein that have they have been grooved or formed into a particulate material, and portions 1604 that have been left without form. The material web 1600 is shown with the carrier band for simplicity. In the embodiment shown in Figure 16, an area 1606 along the longitudinal centerline, L2, of the band 1600 is not formed. There are also areas 1608 that lie along fold lines of prospect, F, which are not formed. The web 1600 is provided with a plurality of portions 1602 that have been grooved or formed into a particulate material that are located on both sides of the longitudinal centerline, L2. These portions 1602 are arranged in rows on either side of the fold lines of the leaflet, F. The pairs 1602 which have been grooved or formed into a particulate material have a circular shape. However, in other embodiments, these areas 1602 may be formed in any other suitable manner. Figure 17 shows the web of material 1600 shown in Figure 16 after the web has been folded longitudinally in several places to a tube-like structure. The web 1600 is folded along the longitudinal center line, L2, and at the fold line, F, to form the structure shown in Figure 17. The non-formed region 1606 along the longitudinal center line adds stability to the structure. The circular portions 1602 comprising the particulate material along the sides of the structure provide these circular regions with improved compressibility and flexibility. The unformed regions 1604 surrounding the portions of circular particulate material 1602 provide stability to the sides of the bent structure. The particulate material will remain in place due to the presence of the carrier band. The unformed regions 1604 can act as a "spring" when compressors are forced to the top or bottom of the bent structure. In the variations of the embodiment shown in Figure 17 (or in any of the other embodiments described herein), the web of material may be provided with grooves running along or traversing the desired fold lines to provide increased flexibility to facilitate the bending of the band and / or so that the band does not fracture when it is bent. Figure 18 shows a tube type structure formed from a web of material 1800 having a triangular shaped groove or portions of particles 1802 formed therein. The web of material 1800 has been folded similarly to the web of material shown in Figure 17. However, in the embodiment shown in Figure 18, the groove or portions 1802 and the surrounding non-formed regions 1804 have different configurations for form a structure of armor type. In any of the embodiments described herein, the mixed band 50 can be bent into different shapes to form other three-dimensional configurations. Some of these configurations are shown in Figures 19 to 23. Figure 19 shows an embodiment wherein the mixed band 50 is bent so that the longitudinal side margins 86 of the mixed band 50 do not extend further towards the central fold., F ^ forming the central lobe 34, as in the embodiment shown in Figure 2. This results in a central lobe 34, which has an upper portion 35 with a reduced transverse width due to the few layers of material that are extend to this portion of the central lobe 34. Said embodiment with a narrower central lobe 34 may be desired by some women for convenience. Figure 20 shows an embodiment wherein the mixed web 50 is bent in an alternative configuration to provide a pair of flexible extensions 2000. As before, the bent band of the absorbent material and the containment band define an inverted U-shaped transverse configuration , central, which forms the upper portion of the bent band (and the central lobe 34). The flexible side extensions 2000 preferably extend laterally outwardly and downwardly from the central lobe 34. As shown in Figure 20, the longitudinal side margins 86 of the composite band 50 are folded out away from the longitudinal center line. L2 of the mixed band 50, instead of inward towards the longitudinal center line as in the case of the previous modalities. This fold creates two U-shaped portions along the lower surface of the bent band of absorbent material, and the longitudinal side margins of the band of absorbent material extend upwardly out of the central inverted U-shaped portion in the direction of the upper portion of the bent band. The longitudinal side margins 86 preferably extend upwardly beyond the bonded area 54. The longitudinal side margins 86 are then bent outwardly away from the longitudinal center line L2 of the mixed web 50, so that they extend outwardly and downwardly. . The flexible side extensions 2000 are preferably able to maintain contact with and cover the inner surfaces of the user's lips when the user's body goes through a range of movements, including squatting. The flexible lateral extensions 2000 also block a direct "line of sight" from the outer perimeter of the labia majora to the vaginal introitus. As a result, the exudates of the body can not "lose" the tube of the absorbent material 22 and the flow of said exudates will be intercepted by the tube of absorbent material 22. The advantage provided by the flexible side extensions 2000 is shown by comparing Figures 21 and 22. As shown in Figures 21 and 22, when the user squat, lips M, have to separate. As shown in Figure 21, without the flexible side extensions 2000, the central lobe 34 of the tube of absorbent material 22 tends to adhere to the lips and shift sideways when this happens. The flexible side extensions 2000 are believed to allow the tube of absorbent material 22 to maintain contact with both inner surfaces of the lips as shown in Figure 22 in order to keep the tube of absorbent material 22 in an appropriate position, instead of adhering to the side of the lips, and moving to that side. The flexible side extensions 2000 can be held in place by exerting a slight laterally outwardly oriented pressure on the internal surfaces of the labia minora, labia majora, or both, of the user. In addition, the flexible side extensions 2000 may comprise a material, such as tissue paper, which will adhere to the naturally moist internal surfaces of the lips. Optionally, the flexible side extensions 2000 may be provided with a biocompatible adhesive to assist adhesion of the flexible extensions 2000 to the internal surfaces of the user's lips. Figure 23 shows that in other embodiments, the mixed band 50 can be bent many times to provide a tube of absorbent material 22 with more than three lobes. Although the three-lobed cross-section of the tube of absorbent material 22 shown in the preceding Figures fits the vast majority of women, in some users, due to the shape of the lips of the woman and the space between the lips, the central lobe can undesirably be flattened and / or pushed towards the lip. The embodiment shown in Figure 23 may be useful in providing a structure that can be adapted to the fixing of said body shapes of the user. Figures 24 and 25 show alternative forms wherein the tube of absorbent material 22 can be attached to the base pad 24. Figure 24 shows an embodiment wherein the tube of absorbent material 22 is integrated into the base pad 24. In the embodiment shown in Figure 24, the outer lobes 36 and 38 are positioned between the topsheet 70 (and any optional secondary topsheet 76) and the absorbent core 74. The central lobe 34 extends upwards through an opening in the upper sheet 70 and the optional secondary upper sheet 76 of the base pad 24. The embodiment shown in Figure 24 provides the advantage of placing the absorbent material in the tube of absorbent material in intimate contact with the absorbent core 74 of the pad of base 24. Figure 25 shows a variation of the mode shown in Figure 24. In the variation shown in Figure 25, the mixed band 50 that is doubled to form the tube of absorbent material 22 is bent in an alternative manner, so that some layers of the material are inserted into the base pad 24. More specifically, the band of absorbent material is bent with the containment band around the axes of fdrigitudinally oriented doubles, so that the bent band of absorbent material and the containment band define a pair of central portions, which have transverse U-shaped configurations that define a transverse U-shaped configuration opposite to each other, and the longitudinal side margins of the bent band of absorbent material extend laterally outwardly at the base of the bent band of the absorbent material. This variation produces a less pronounced change in the caliber of the portion of the base pad 24, where the tube of absorbent material 22 is inserted (or tucked in). It also provides the tube of absorbent material 22 with a central slot longitudinally oriented to 2500, which may be useful in acquisition of cellular waste and similar aspects contained in blood-based fluids, such as menstruation. Figures 26 and 27 show one embodiment of a sanitary napkin 2620 which illustrates another form in which a tube of absorbent material 2622 can be integrated into the base pad 2624. (The sanitary napkin 2620 shown in Figures 26 and 27 also comprises a pair of fins 1616). In the embodiment shown in Figures 26 and 27, the web of absorbent material 2642 that is bent to form the tube of absorbent material 2622 is placed below the topsheet 2670 of the base pad. The bent band of absorbent material 2641 also forms the absorbent core 2642 also forms the absorbent core of the base pad, so that a separate absorbent core is not necessary. The absorbent material in the tube of absorbent material and the absorbent core of the base pad can, thus, be described as being "homogeneous". The embodiment shown in Figures 26 and 27 also shows an alternative way to form the tube of absorbent material in a montelillo, which is confined to the central region 2632 of the sanitary napkin 2620. Figure 28 shows that this modality is constructed by cutting the strip of absorbent material in an H-shaped configuration before it is bent to form the tube of absorbent material. This produces the structure shown in a plan view in Figure 26, and in cross section in Figure 27. The cross section of the absorbent material 2642 defines a structure in the form of "mini mushroom" more specifically, the strip of absorbent material 2642 has an inverted U-shaped bent portion having a top portion oriented along the longitudinal centerline of the sanitary napkin in a longitudinally oriented central region of the sanitary napkin, which defines the "cap" "of the mushroom-shaped structure. The two halves of the strip of absorbent material 2642 on either side of the longitudinal centerline each is folded upwardly into an inverted U-shaped cap, and then down to form the "rod" of the mushroom-shaped structure. . The longitudinal side margins 2686 of the bent band of absorbent material 2642 extends laterally outwardly at the base of the bent band of absorbent material to form the absorbent core 2674 of the base pad 2624. In this, or any other embodiment As described herein, the web of absorbent material (such as 2642) can be slit in the central portion (or any other desired portion) for additional flexibility and / or improved comfort. Suitable patterns for grooving the absorbent material are described in U.S. Patent No. 5,611,790 issued to Osborn et al. Figure 27 shows that in this particular embodiment, the folded absorbent material 2642 is preferably covered by a secondary topsheet 2676. Furthermore, the upper portion of the mushroom-shaped structure has a fiber mattress of an acquisition material, such as a high fluff material 2634 on it. The fungus design concentrates the absorbency at the center of the product. The high fluffiness material 2634 provides rapid acquisition of body exudates. The high-fluff material 2634 can provide faster acquisition than the absorbent material 2642 to increase the total acquisition velocity of the absorbent material tube 2622. The high-fluff material 2634 also provides elasticity and a dynamic fit closely conforming the body configuration of the user and adjusting the forces placed on it by the user's body. The high-fluff material 2634 can extend any length of the tube length of absorbent material 2622. Preferably, in the embodiment shown, the high-fluff material extends beyond the ends of the mushroom-shaped structure and substantially all of the length of sanitary napkin 20. (it should also be understood that said high fluff material may also be used in any of the other embodiments described herein). The components of the sanitary napkin embodiment shown in Figure 26 and 27 may comprise any suitable materials. These materials may include any of those materials specified above as being suitable for the corresponding components of the embodiments shown in the preceding drawings. Preferably, in this embodiment, the components of the sanitary napkin 2620 comprise the following materials. The topsheet preferably comprises a film with DRI-WEAVE openings. The high-fluff material preferably comprises a non-woven fibrous, polyester, carded, thermally bonded material having a gauge of about 4 mm, a basis weight of about 51 grams / m2, and a density of 0.0077 g / cm3, which is obtained from product code # W-4635 from Stearns Technical Textile of Cincinnati, Ohio. The secondary topsheet preferably comprises a nonwoven polypropylene material of fused together filaments of 22.5 g / m2 named as a product No. 0.65 MLPV60U (or "P-9"), obtained from Fiberweb, North America of Washougal, WA. The web of absorbent material preferably comprises a multi-junction air-laid non-woven material, which comprises about 20% absorbent gelling material, cellulose fibers, powder binder and latex binder, having a caliber of approximately 2 mm and a basis weight of approximately 120 g / m2. (Unless otherwise indicated, all percentages here are weight). Such multi-junction air-laid non-woven material is obtained as the VIZORB 3900 nonwoven from Buckeye Canada, Inc., Delta, B. C, Canada. The backsheet 26 72 and the adhesive fasteners 2690 and 2696 may be any conventional materials used for these components. The entire assembly of the absorbent material web 2642, the secondary topsheet 2676 and the fibrous mattress of high-fluff material 2634 is preferably covered by the topsheet 2670. Thus, in this embodiment, the web of absorbent material 2642 fully integrated into the base pad 2624 to form a longitudinally oriented absorbent horn. In this particular embodiment, the hillock is held in place through fusion junctions 2636 that are preferably located at or slightly away from the base of the hillock. The melt bonds 2636 preferably fully penetrate through all the components of the sanitary napkin 2620. The melt bonds 2636 can also serve to prevent the exudates from penetrating laterally out of the absorbent hillock. The fusion junctions 2636 may be of any suitable configuration. As shown in Figure 26, in this embodiment, the fusion junctions 2636 are preferably in the form of straight longitudinally oriented lines extending the length of the sanitary napkin. Figure 29 shows another variation of a sanitary composite pad 2920, wherein the absorbent material 2942 is folded and fully integrated into the base pad 2924. The absorbent material 2942 shown in Figure 29 is folded into a shape that provides a central fold 2946 that is greater than the folds located laterally outward of the central fold. The folding provides the sanitary napkin 2920 with the 2922 configuration of the desired montecillo. The unfolded longitudinal side margins of the web of absorbent material 2942 extend outwardly to form the absorbent core 2974 of the base pad 2924. The absorbent material 2942 in this embodiment may, but not necessarily, be cut into a shape-shaped configuration. of H before doubling in the manner described for embodiment shown in Figures 26 and 27. The sanitary napkin 2920, like the above embodiments, also comprises a topsheet 2970, a backsheet 2972 and a secondary topsheet 2976. shown in Figure 29 may be provided with a number of optimal components and / or features. The embodiment shown in Figure 29, like any of the other embodiments described herein, may also be provided with a visual indicator, such as a strip of color material 2938. This color material 2938 may be used to provide a visual signal to the user that the absorbed liquids are mainly retained in the center of the sanitary napkin. This can be used to alleviate the user's concerns that the absorbed liquids are traveling towards the longitudinal side edges of the product, where they may tend to cause staining of the wearer's underwear. In the embodiment shown in Figure 29, or any of the other embodiments described herein, all or a portion of the topsheet can be mechanically modified to have improved smoothness. For example, it may be desirable to mechanically modify the portion of the topsheet 2970 that covers the hillock. Suitable types of processes for mechanically modifying the topsheet (and / or other components of the sanitary napkin, include, but are not limited to, passing the topsheet through a nozzle between slotted or patterned rolls., a process that has been described as pre-corrugation (or "ring rolling") and forming the components to a structural elastic-type film material (or "SELF" material), a process that has been termed as " SELFing "" for brevity Suitable methods for ring winding are described in US Patent 4,107,364 issued to Sisson et al. On August 5, 1978; U.S. Patent No. 5,143,679 issued to Gerald M, Weber et al., the 1st. September 1992; U.S. Patent No. 5,156,793 issued to Kenneth B. Buell et al., October 20, 1992; and U.A. Patent 5,167,897 issued to Gerald M. Weber et al., the 1st. December 1992. A SELFing method of a web of material is described in US Patent 5,518,801 issued to Chapell et al. on May 21, 1996. Certain types of mechanical modification (ring winding and SELFing) may also provide the topsheet with the ability to extend to cover the central portion of the tube of absorbent material (e.g., the portion comprising the mushroom-shaped band in Figures 26 and 27) without "overwetting" excessively on portions of the regions end of the tube of absorbent material. Figure 30 shows another alternative embodiment of a sanitary napkin 3020. The sanitary napkin 3020 also has a topsheet 3070, a backsheet 3072 and an optional secondary topsheet 3076. The embodiment shown in Figure 30 has an absorbent web 3042 that It is bent in half in a "V" shaped transverse configuration. In cross section, this bent band 3042 appears to have two "limbs" that are connected at the top. The embodiment shown in Figure 30 may employ a relatively low cost absorbent material that is bent less than the structures described in the preceding embodiments. The embodiment shown in Figure 30 is intended to provide at least some of the benefits of the structures described above. The absorbent material 3042 preferably has a larger caliper (e.g., about 10-12 mm) under a confining pressure of 6.9 kPa than the absorbent material used in the above embodiments. This has a longitudinally oriented compression line 3046 below the center where it is bent. The absorbent material 3042 is compressed to a gauge of about 1-2 mm in the region of the compression line 3046. In addition to assisting the absorbent material 3042 in the fold, the compression line 3046 can help direct the exudates of the body in the longitudinal direction to make use of the full capacity of the absorbent material 3042, as much as possible. The absorbent material 3042 used in the embodiment shown in Figure 30 may comprise a number of suitable higher caliper materials. These include, but are not limited to: cotton, thermally bonded air-laid non-woven materials, and multi-junction nonwoven materials. Preferably, the highest gauge material measures approximately 20 cm x 2.5 cm, and is capable of retaining 30 grams of menstruation under a pressure of 69 kPa. A suitable material is a thermally bonded nonwoven web material comprising approximately 20% absorbent gelling material, two-component fibers, and cellulose fibers. The advantage of using such high caliber materials is that they provide a high absorbent capacity in the center of the sanitary napkin. The absorbent capacity can be sufficiently high that a tissue paper such as the absorbent core 3074 of the base pad 3024 can be used to reduce the cost. A tissue paper suitable for use as the absorbent core comprises a piece of BOUNTY paper towel obtained from The Procter & Gamble Company of Cincinnati, Ohio. Figure 31 shows another more alternative embodiment of a higher bent gauge absorbent web, 3142. The absorbent web 3142 shown in Figure 31 is folded into a three-lobed configuration. The web of absorbent material 3142 may comprise any of those materials specified above for the preceding embodiment. The embodiment shown in Figure 31 is formed by making three longitudinally oriented compression lines 3146 on the strip of absorbent material 3142 and then bending them in the configuration shown. The compression lines 3146 in the absorbent material 3142 not only help to bend the absorbent band, but also provide the absorbent material 3142 with the ability to direct the flow of liquid exudates. Liquids will tend to penetrate toward and along the 3146 compression lines through capillary action. In other embodiments, the pattern of compression lines can be varied to alter the penetration characteristics. In any of the embodiments described herein, the height (or gauge) of the tube of absorbent material 22 may vary over any portion of its length. For example, Figure 32 shows a modality in which the height of the tube increases from the front of the sanitary napkin to the back of the sanitary napkin. This can be used to provide better comfort and contact with the wearer's body in the area of the slit between the wearer's gluteus (or "gluteal groove") for example, the strip of absorbent material shown in Figure 31 may have a Triangular plan view configuration. When folded, the back of the product will assume the configuration shown in Figure 31, but the front of the band can be flattened to provide the sanitary towel in the manner shown in Figure 32. Figures 33-35 show another form to form a tube of absorbent material with different calibers along portions of its length. As shown in Figure 33, to form such a structure, the end regions of a strip of absorbent material (or a mixed web of absorbent material, or a whole sanitary napkin 3320) can be mechanically stretched (such as by winding the ring or SELFing) to form the strip of absorbent material in an hourglass-shaped configuration. The hourglass-shaped band is gathered inward along its longitudinal centerline L2 to form a hillock as shown in Figure 35. The assembled band of sanitary napkin (or sanitary napkin) can be retained in the region of its transverse center line T2 to form a longitudinally oriented absorbent montecilus having a greater caliber in its central region than in its extreme regions, but is narrower in the central region than in its extreme regions. In other embodiments, a band of material in the shape of an hourglass can be used, which is not mechanically stretched. In other embodiments, the gathering of the strip of absorbent material can lead to the longitudinal edges of the strip inwards. The longitudinal edges of the band can be gathered inward in the end regions of the band, so that they form straight lines (ie, the band no longer has the shape of an hourglass). This will result in the portion of the hillock formed in the end regions having a greater caliber than the portion of the hillock in the central region, and can be modified to have either a greater, lesser width, or the like, compared to the portion of the hillock in the central region of the sanitary napkin. Preferably, the different portions of the hillock taper gradually towards each other, so that there is a moderate transition between them. A non-limiting number of variations of the modality shown in Figures 33-35 is also possible. In one variation, the web of absorbent material can be mechanically modified in different ways before it is assembled to form a hillock. For example, a strip of absorbent material (or an entire absorbent article) can be provided with grooves similar to those shown in Figure 15 before being gathered to form a mound. The region along all or a portion of the longitudinal center line of the web of absorbent material can be SELFed both in the longitudinal direction and in the transverse direction to form a plurality of particles of absorbent material (as will be described in more detail). ahead) in this region. The surrounding regions or adjacent regions may be provided with a plurality of longitudinally oriented slots similar to the strip of absorbent material shown in Figure 15. After the meeting, this will result in the portion of the strip of absorbent material forming the hillock comprising a plurality of particles of absorbent material, and the surrounding portions comprising a plurality of strips of absorbent material. Alternatively, the surrounding regions can be left as a solid piece of material without grooving them. These embodiments may provide the sanitary napkin with a number of desired properties, only in a less complicated manner. Figures 36-38 show several possible ways in which the tube of absorbent material 22 in particular one not integrated (or tube of separate absorbent material) can be attached to the base pad 24. Figure 4 previously shows a mode wherein the tube of absorbent material 22 was attached along its entire length to the base pad 24. Figure 36 shows an embodiment wherein the ends of the tube of absorbent material 22 are attached to the base pad 24, and the tube portion of absorbent material 22 between its ends is not attached to the base pad 24. Figure 37 shows an embodiment wherein the tube of absorbent material 22 is permanently attached at one end to the base pad 24, and the other end is releasably attached to the base pad 24. Figure 38 shows an embodiment wherein the tube of absorbent material 22 is releasably attached to the base pad 24 in both of its ex tremos. The ends of the tube of absorbent material 22 can be releasably attached to the base pad 24 in a suitable manner. In the embodiments shown in Figures 37 and 38, the bottom portion of the ends of the tube of absorbent material 22 is provided with an adhesive, such as a pressure-sensitive adhesive patch 95. The adhesive patch 95 is releasably attached to an adhesive. underlying releasable material, such as a release paper 96 of the type conventionally used to cover pressure-sensitive adhesives on absorbent articles. Preferably, as shown in Figure 37, the end 96A (or as shown in Figure 38, both ends 96A and 96B) of the release paper can be folded over a portion of the side facing the base pad body 24. and positioned between the ends of the underlying absorbent material tube 22 and the body facing side 24A of the base pad 24. The provision of a releasable joint between one or both ends of the tube of absorbent material 22 provides the ability to allow an end, or both ends of the tube of absorbent material 22 move from the base pad 24, if said freedom of movement is desired for body adjustment. The provision of a releasable joint at both ends of the tube of absorbent material 22 allows the tube of absorbent material 22 to be removed and repositioned on the base pad 24 at a location desired by the user. This is particularly useful when the absorbent material tube 22 is already more honest in the base pad 24, and the base pad 24 is relatively long and / or asymmetric around its transverse center line. Further, if the tube of absorbent material 22 is stained, but the base pad 24 does not, the provision of a joint at both ends of the tube of absorbent material 22 also allows the tube of absorbent material 22 to be replaced. In any of the embodiments described herein, the base pad 24 may optionally be provided with a movable region or area 3900 as shown in Figures 39 and 40. The movable area 3900 may be used in conjunction with a pipe of absorbent material 22 by a user to insert one or more of his fingers, or portions thereof, in order to assist in the desired placement of the tube of absorbent material 22. the movable area 3900 will typically comprise a depression in the absorbent material, such as a slot or opening in the absorbent material that can be adapted to the desired portions of the fingers or the user's hand. Preferably, the depressed portion of the base pad 24 comprises an extension material 3902 to cover the user's fingers when he inserts his hand in the depressed area. Preferably, the extension material 3902 comprises extension portions of the topsheet and the backsheet. The extension portions of the topsheet and the backsheet are preferably coplanar with the surrounding portions of the topsheet and the backsheet until a user inserts their fingers therein. After a user inserts his or her fingers said movable area, the portions of the topsheet and the backsheet can extend beyond the plane of the topsheet and the backsheet to move the non-peelable area to a closeness to the space between them. the lips of the user.

The extension material 3902 may comprise any suitable extension material. In preferred embodiments, as shown in Figures 39 and 40, the extension material may comprise portions of the topsheet and the backsheet that can be made extensive through ring-ring winding or SELFing. These processes can be used to provide these portions of the topsheet and the backsheet with an extension capacity that varies as much as 100% to 200%. Further, if desired, the extension material 3902 in the depression can also be provided with an absorbent material between the extension portions of the topsheet and the backsheet to provide the pad with a degree of absorbency. In a variation of this embodiment, a base pad 24 (e.g., an ultra thin sanitary napkin) having this feature, can be used as an independent product without the tube of absorbent material on its top. Figures 41 and 42 show a modality of a composite sanitary napkin, which has an alternative adjustment aid mechanism. In the embodiment shown in Figures 41 and 42, the adjustment assist mechanism in the form of a removable strap, such as a strip passing through (e.g., the upper part of the central lobe) tube of absorbent material 22 The user can hold both ends of the strip to pull the tube of absorbent material 22 moderately towards the desired fixing condition between the lips after the compound sanitary napkin is put in place in the panties and the panties are placed in a usual way The strip can then be removed when the sanitary napkin is used by pulling the strip at one end of the tube of absorbent material 22. The sanitary napkin 20, in any of the embodiments described herein, may also comprise wings or wings for wrapping around the side sides of the leg portion of the wearer's underwear. Typically, said fins extend laterally outwardly from at least the central region 32 of the main body portion of the sanitary napkin 20. Suitable fins and other types of lateral wrapping elements are described in reexamined patent No. B1 4,589,876 entitled 2 Sanitary Napkin, issued to Tilburg, Certificate of Reexamination issued on April 27, 1993, US Patent 4,687,478 entitled "Shaped Sanitary Napkin UIT Flaps" (Sanitary Towel Configured with Fins), which was issued to Van Tilburg on August 18, 1987; US Patent 5,281,209 entitled "Absorbent Article Having Tucked Flaps", which was issued to Osborn et al. on January 25, 1994; US Patent 5,389,094 entitled "Absorbent". Article Having Flaps and Zones of Differential Extensibility "(Article Absorbent that Has Fins and Zones of Differential Extension Capacity) e xpedida to Lavash et al. on February 14, 1995; US Patent 5,558,657 entitled "Absorbent Articles Having Overlapping Undergarment Components That Automatically Wrap the Sides of Undergarments" (Absorbent Articles Having Overlapping Underwear Components Automatically Wrapping the Sides of Underwear), issued to Hammons et al. on September 24 of 1996; International Patent Application Series No. PCT US 96/15957 entitled "Absorbent Article Having Flaps UIT Step Configuration and Zones of Extensibility" (Absorbing Article Having Fins with a Configuration Step and Extension Capacity Zones), filed on October 3 of 1996 in the name of Lash and others; and U.S. Patent No. 5,669,898 entitled "Absorbent Article ITU Adjustable Undergarment Protection System" (Article Absorbent with an Adjustable Lingerie Protection System) issued to Ahr on September 23, 1997. 2. Method for Making the Sanitary Towel The sanitary napkins described herein can be made through any suitable process.

A. METHOD FOR MAKING THE TUBULARLY FORMED OR CONFORMED ABSORBENT PIPE FIGURES 43-50 show a preferred process for making the absorbent material tube 22 three dimensionally configured to be placed on the body facing side 24A of a base pad 24 for forming the composite sanitary napkin shown in Figures 1 and 2. However, the various embodiments of the sanitary napkin of the present invention are not limited to being made through the process shown in the drawings. It should be understood that a number of the steps shown in Figures 43-50 are optional, but preferred and, thus, are shown, since they are useful for making the tube of absorbent material shown in Figures 1 and. (1) Component Assembly Figure 43 shows a mixed web of material 120 that will be configured to the three-dimensionally formed absorbent material tube 22 for use in the sanitary pad shown in Figure 1. The mixed web of material 120 shown in the Figure 43 comprises a first web of material 122 that will form the absorbent material 42 in the tube of absorbent material 22. The first web of material 122 is preferably an absorbent material, such as an absorbent foam material. Preferred absorbent foam materials are those described in the aforementioned absorbent foam material patents. Preferred absorbent foam materials are generally incompatible with bonding using conventional techniques, such as adhesives, heat and / or pressure, and ultrasonic bonding. The first band of material 122 in this manner can also be referred to as the "band of incompatible material". The strip of absorbent foam material 122 has a first bonding capacity (ease of bonding). The web of absorbent foam material 122 may, but not necessarily be, completely incompatible with conventional bonding techniques.

Alternatively, it may be a material to which other materials merely can not be easily joined using such techniques. The strip of absorbent foam material has a first surface 122A and a second surface 122B. The bonding capacity of the first strip of material 122 should be taken into account when assembling the tube of absorbent material, especially when it is necessary to join the bent mixed band 120 in order to retain it in its bent configuration. The strip of absorbent foam material 122 may not be readily capable of bonding for any or many reasons. Frequently, said materials are incompatible with conventional joining techniques due to their structural integrity or composition. It is difficult to bond other materials to these materials using adhesives, since the structural integrity of these materials is usually not as strong as bonding adhesive. As a result, only portions of the absorbent foam material that are in direct contact with the adhesive will remain attached to other materials. The rest of the absorbent foam material will easily be separated from the material to which it is attached. In addition, the foam materials described in the absorbent foam material patents can not be bonded to other materials using heat bonds, since these foams are heat setting polymers. Once they are formed, they can not be remelted. Rather, when heat is applied to these foam materials, they will burn instead of melting and flowing, which is necessary for bonding with heat, these foam materials can not be attached with pressure to other materials, since the Thermo-fixation foam materials do not have the ability to flow and be fused under pressure. The strip of absorbent foam material 122 in the embodiment shown in Figure 43 is at least partly wrapped in a second material web 124. The second material web 124 preferably has a second bonding capacity that is greater than the capacity of Bonding of the strip of absorbent foam material 122. That is to say, the second web of material 124 preferably can not be easily bonded to other materials using conventional bonding techniques. The second web of material 124 may also be referred to herein as "a carrier web" or a "junction capable web". The sanitary napkin of the present invention, however, is in no way limited to articles comprising a band of absorbent foam material that is surrounded by a web of material having a superior bonding capacity. The second web of material 124 is preferably made of a material that is capable of being bonded to other materials, or likewise through heat and / or pressure, or ultrasonic bonding. The second web of material 124 can be manufactured from any of the materials specified above being suitable for use as the topsheet 40 and / or the containment web 44. The second web of material 124 can be made from a wide variety of materials such as woven and non-woven materials; polymeric materials such as thermoplastic films formed with openings, plastic films with openings and without openings, and hydroformed thermoplastic films; porous foams, cross-linked foams; crosslinked thermoplastic films; and thermoplastic canvases. In other embodiments, the second web of material 124 can be replaced by a material that is in forms other than a web of material. For example, the second web of material 124 can be replaced by a layer or liner capable of bonding such as an extruded rubber liner or a silicone liner that is applied to the web of absorbent foam material 122. For this reason, the second web of material 124 can be referred to as "the second material", so that it is evident that materials other than webs are included. Preferably, the second material 124 comprises a web of material that is also suitable for use as a wrap for the absorbent material 44 in the tube of absorbent material 22. In the preferred embodiment shown, after processing, the second web of material 124 will serve as the containment band 44 for containing the absorbent material in the tube of absorbent material 22. The second material web 124 preferably comprises a band made of a spunbond nonwoven material. A particularly preferred spunbond nonwoven material is a 22.5 g / m 2 spin-bonded polypropylene nonwoven material referred to as the product No. 065MLPV60U (or "P-9") obtained from Fiberweb, North America of Washougal, WA. Another particularly preferred nonwoven material is a spunbond polyethylene nonwoven known as COROLIND sold by Corovin GmbH Peine, Germany, which can be obtained in two basis weights 23 grams and 30 grams. As shown in Figure 43, the second web of material 124 is preferably completely wrapped around the web of absorbent foam material 122, so that the second web of material 124 has a cross-sectional configuration folded into a web-like shape. ). Although the second web of material 124 is wrapped around the web of the compatible material 122 in an e-folded configuration, it should be understood that the second web of material 124 is not limited to wrapping the web of incompatible material 122 in a folded configuration. in the form of "e". In other embodiments, the second web of material 124 can only be at least partially folded or wrapped around the web of absorbent foam material 122. The second web of material 124 can be folded or wrapped around the absorbent foam material 122 in any other suitable configuration. Other suitable configurations include, but are not limited to, C-shaped configurations and the like. It is also necessary that the second web of material 124 be limited to a single web that wraps the web of absorbent foam material 122. One (or more) web of material can be placed adjacent each web surface 122A and 122B of the web of material of absorbent foam 122. For example, in other embodiments, there may be two bands of the second material 124, one of which is positioned adjacent each surface 122A and 122B of the strip of absorbent foam material 122. In other embodiments, both Bands of material that are placed adjacent each surface 122A and 122B of the strip of absorbent foam material 122 may differ. For example, they can be different types of materials, or they can be of the same basic types of materials, but have different characteristics (such as caliber, etc.). (2) Formation of Absorbent Material to a Particle Material In the preferred embodiment of the process for making the tube of absorbent material 22 shown in the drawings, a single band bent in the shape of an "e" is used. In an especially preferred embodiment of this embodiment, the web of absorbent foam material 122 will be formed into the particulate material while it is within the second web of material 124. This will be done through the process described in the US patent application. commonly assigned Series No. 09 / 027,379, entitled "Method of Making a Slipped or Particulated Absorbent Material and Structures Formed Thereby" (Method for Making a Slotted Absorbent Material or in Particles and Structures Formed Through It), and "Method of Making a Slitted or Particulate Absorbent Material ", submitted in the name of Ronald R. McFail et al. on February 20, 1998.

In such a case, it is preferred that the second web of material 124 not only be able to be more unbreakable than the web of absorbent foam material 122, but also have a greater break point relaxation than the web of absorbent foam material 122. This operation (forming the absorbent foam material to a particulate material) is an optional, but preferable, step for making the particular embodiment shown in Figures 1 and 2. If the absorbent foam material is to remain in the sheet form, then this step will be omitted. The preferred process for forming the absorbent foam material 122 to a particulate material shown in the drawings comprises several steps. A "carrier band" is provided having a first break point to break under tension forces. (In the embodiment described here, the second web of material 124 serves as the carrier web). The web of material for forming the particulate material (which in this case is the strip of absorbent foam material 122) and the carrier web are then formed into a mixed web 120. The foam absorbing material 122 has a second point of relationship to rupture under tensile forces that is less than the point of relaxation at break of the nonwoven carrier web 124. The nonwoven carrier web 124 may, if desired, be attached to the web of absorbent foam material. Although the absorbent foam material is incompatible with conventional bonding techniques, if the mixed web 120 is not subjected to excessive release forces, a relatively low level of bonding is sufficient for the purposes described herein. If bonded, the nonwoven carrier web 124 is preferably bonded to the web of absorbent material through adhesives in an open pattern network of filaments of adhesives as is known in the art. An apparatus for mechanically reinforcing the mixed band 120 is provided. The apparatus preferably comprises a compression device having at least one component with at least one surface in patterns thereon. The mixed web 120 is then preferably subjected to a mechanical stressing process. In the mechanical tensioning process, the apparatus prints a surface in patterns in the mixed web 120, so that the foam absorbent material 122 is at least partially formed into a particulate material without forming the carrier web (second web of material ) 124 to particulate material. Figure 44 shows an embodiment of an apparatus 130 which is used to form the absorbent material 122 in the mixed band 120 to a particulate material. The apparatus 130 shown in Figure 44 comprises two pairs of cylindrical rollers, a first pair of rollers 132 and a second pair of rollers 162. Each of the rollers has a patterned surface thereon. The preference patterns are formed through a plurality of ridges and valleys on the rollers defining a plurality of triangular-shaped teeth. The first pair of rollers 132 comprises an upper roller 134 and a lower roller 136. The rollers 132 and 134 have separate axes, R. Each of the rollers has a pattern on its surface. In Figure 44, the upper roller 134 has a plurality of ridges 138 and valley 140 that are arranged around the circumference of the cylindrical roller 134. The ridges 138 form a plurality of triangular-shaped teeth 139 on the surface of the upper roller 134 when the upper roller 134 is seen in cross section. Preferably, teeth 139 have cross sections in the shape of isosceles triangles. If desired, the apex of the teeth 139 may be slightly rounded. The teeth 139 on the upper roller 134 can be of any suitable size and pitch. The term "step", as used herein, refers to the distance between the vertices of adjacent teeth. In the preferred embodiment shown in the drawings, the depth (or height) of the tooth used is preferably. from about 2.5 mm to about 4.3 mm. The pitch is preferably between about 1 mm and about 5 mm, and most preferably is between about 1.5 mm and 2.5 mm. The passage of the teeth establishes the width of the strips where the absorbent material is cut or shredded. The lower roller 136 of the first pair of rollers shown in Figure 44 also comprises a plurality of flanges 142 and valleys 144 that are disposed around its circumference. The ridges form a plurality of triangular-shaped teeth 143 on the surface of the lower roll 136. The teeth 143 on the bottom roll 136 preferably have cross sections in the shape of isosceles triangles. The teeth 143 on the lower roller 136 are preferably of the same size as those of the upper roller. The lower roller 136 preferably also comprises several thin flat channels 146, uniformly spaced over the surface of the lower roller 136 which are oriented parallel to the axis, R, of the lower roller. In this embodiment, the separate channels 146 in the lower roller 136 preferably have a width of 2 mm. The "length" of the teeth 143 in the lower roller 136 measured around the circumference of the lower roller between the separate channels is 8 mm. A roller with patterns suitable for use as the bottom roller is described in U.S. Patent 5,518,801, entitled "Web Materials Exhibiting Elastic-Like Behavior" (Band Materials Exhibiting Elastic-Type Behavior) issued to Chappell et al. May 1996. The triangular-shaped teeth 139 in the upper roller 134 are preferably deviated from the teeth 143 on the lower roller 136. The deflection is such that the triangular-shaped teeth 139 in the upper roller 134 are aligned with the teeth. valleys 144 on the lower roller 136. That is, the teeth on the upper roller 134 are centered relative to the valleys 144 on the lower roller 136 and can mesh (or "attach") the lower roller portions 136 that define the valleys 144 on the lower roller 136. In this embodiment, however, the rollers are preferably separated, so that the teeth 139 are triangular in shape. upper roller 134 only partially engages valleys 144 on lower roller 136. Rolls 134 and 136 are preferably directed in opposite directions. The degree to which the teeth on the opposite rollers mesh is referred to herein as the "coupling" of the teeth. The coupling of the teeth is the distance between a position where the vertices of the teeth on the respective rollers are in the same plane (0% coupling) to a position where the vertices of the teeth of a roller extend inwards towards the valleys on the opposite roller. The coupling of the teeth can be expressed as a percentage of the step (distance between the vertices of the teeth on one of the rollers), or in terms of a measured distance. Since the height of the teeth may be greater than the pitch, the coupling may be of a value that is greater than 100% (for example if the coupling is larger than the pitch). Preferably, the coupling is between about 15% and about 120% of the passage length, and most preferably between about 65% and about 100% of the passage length. The coupling expressed in terms of a measured distance of preference is between about 0.25 mm to about 1.8 mm, and most preferably between about 1 mm and about 1.5 mm. As shown in Figure 44, in the step designated A, the composite web 120 is fed in a machine direction (MD) in a nozzle between the rollers 134 and 136. The second web of material 124 supports and contains the web. absorbent foam material 122, which is close to being grooved and formed into a particulate material. The second web of material 124 wraps the outer part of the strip of absorbent foam material 122, so that the second web of material 124 looks at the surfaces in patterns on rollers 134 and 136. Rollers 134 and 136 subject the mixed web 120 to a mechanical tension process by printing the surfaces with patterns in the mixed web 120. The mechanical tension process applies a force that is greater than the break-away point of the absorbent foam material web 122, but less than the breaking point of the nonwoven carrier web 124, so that the web of the absorbent foam material 122 is at least partially grooved without grooving the carrier web 124. Figure 44 shows the condition of the mixed web in step B, after it passes after the nozzle between the first pair of rollers 132. As shown in Figure 44, the carrier band 124 will have a pattern formed therein that corresponds to the combination of the patterns on the adjacent rollers, 134 and 136. The carrier band 124, however, is not slotted or cut. The intermediate band of the absorbent foam material 122 has a plurality of grooves 150 formed therein. The grooves 150 are oriented in the machine direction ("or" MD "). In the particular embodiment shown, the grooves are intermittent and are separated by machine directional strips (or" CD ") of non-grooved material. 152. This is due to the presence of the channels 146 on the lower roller 136. The band of absorbent foam material 122 is grooved, while the carrier band 124 is not grooved, since the band of absorbent foam material 122 has a breaking point to the break lower than the carrier band 124, and breaks, under tensile forces (the tension process) while the carrier band does not break The band of absorbent material 122 does not need to have webs of material without grooves 152. In other embodiments, continuous grooves may be formed in the web of absorbent material 122. The continuous grooves 150 will be formed if the lower roller 136 is modified by replacing the channels 146 therein with tions that form continuous ridges and valleys. In such embodiment, the lower roller 136 will be identical to the upper roller 134. If the grooves 150 are continuous, the band of absorbent material 122 will be formed into a plurality of strips 151 that have been separated by the grooving process. These may be referred to as "strands" herein, although they are not composed of bonded fibers or the like. These strips 151 may be narrow, or they may be quite wide, with widths increasing slightly less than the width of the band (depending on the apparatus used). If the strips 151 are very narrow, they may resemble nodules of spaghetti in all dimensions. However, the sides of these strips can typically be flat instead of round. The width of the strips 151 depends on the pitch of the teeth in the rollers. In this way, some non-limiting dimensions of the strips 151 in the preferred embodiment shown may vary from about 1 mm to 5 mm in width, and preferably have a width of between about 1.5 mm and about 2.5 mm. The strips 151 may be of any suitable length. They can vary in lengths that are slightly larger than their width dimension to an infinite length. Typically, their maximum length will be limited by the length of the product in which they are incorporated. At this point in the process (in step B, between the first and second roller groups 132 and 163), it is possible to perform additional operations in the mixed band 120. For example, the mixed band 120 can be cut in discrete stretches between the first and second roller groups 132 and 162. In other embodiments, the mixed band 120 can be cut in discrete lengths by a cutting blade located on one of the rollers of the first roller group 132. In other embodiments, as shown in FIG. Figure 48, the mixed band 120 can be cut in discrete sections by a cutting blade located on an apparatus that the mixed band passes through subsequent to the second group of rollers 162. The lengths correspond to such size of the desired tube for the sanitary napkin shown in Figure 1. The cut of the mixed band 120 has been omitted from Figure 44 to simplify the illustration. In addition, a strip of additional material, such as a sheet of film top sheet material with opening 156, can be joined to the mixed band 120. Said sheet of top sheet material will be the top sheet 40 in the sanitary pad shown in FIG. Figures 1 and 2. The band of additional material can be joined to the mixed band 120 at any suitable place in the process. For example, the additional band can be joined to the mixed band 120 before or in the first roller group 132, between the first and second roller groups, or in or after the second group of rolls 162. The upper sheet material can be in the form of a continuous band, or in the form of individual pieces corresponding to the size of the tube desired for the sanitary napkin shown in Figure 1. The joining of the upper film material of apertured film 156 to the mixed band 120 is shown in Figure 45. It has also been omitted from Figure 44 to simplify the illustration. The apertured film upper sheet material 156 is preferably bonded to the mixed web 120 through adhesive. This forms a structure which will be referred to herein as a "mixed tube forming band" 188. The second roller group 162 of apparatus 130 for mechanical tension of the mixed band is shown in Figure 44. The second roller group 162 also comprises upper and lower rollers 164 and 166, respectively. Each of these rollers also has a pattern on its surface. As shown in Figure 44, the upper roller 164 has ridges running parallel to the axis of the upper roller 164 which is oriented so as to define teeth 168 with a triangular shape. The upper roller 164 also has a plurality of spaced channels 170 that are oriented around the circumference of the cylindrical roller. The lower roller 166 of the apparatus shown in Figure 44 is similar to the upper roller 164. Patterned rollers suitable for use as the rollers in the second pair of rollers 162 (although not for this purpose) are described in greater detail in the patent US 5,518,801 entitled "Web Materials Exhibitng Elastic-Like Behavior" (Band Materials Exhibiting Elastic-Type Behavior) issued to Chappell et al. on May 21, 1996.

In the preferred embodiment in the drawings, upper and lower rollers 164 and 166 in the second group of rollers 162 have teeth and ridges and valleys having similar characteristics to those elements of the first group of rollers. In this way, the teeth preferably have the shape of isosceles triangles. The teeth of preference also have the same step. However, in other embodiments, the pitch of the teeth in the second group of rollers 162 may be smaller or larger than the pitch of the teeth of the first group of rollers 132. In the preferred embodiment shown, the separate channels 170 and 178 in FIG. the second group of rollers preferably have a width of 2 mm. The "length" of the teeth measured transversely across the rollers (parallel to the axes, R) between the separate channels 170 and 178 on the surface of each roller is 8 mm. The triangle-shaped teeth on the upper and lower rollers also preferably have the same coupling as the teeth of the first group of rollers, although the coupling can also be varied. The upper and lower rollers preferably rotate in opposite directions. The mixed band 26 is similarly fed to the nozzle between the rolls 164 and 166. Figure 44 shows that when the mixed band 120 leaves the nozzle between the second group of rolls 162, at least a portion of the absorbent foam material 122 also it is provided with a plurality of grooves 180 which are oriented in the direction transverse to the machine. This initial grooving in the machine direction and the subsequent grooving in the machine transverse direction results in the absorbent material 122 being formed or crumbling into a plurality of particles 182. In the preferred embodiment shown in the drawings, the particles 182 have a square surface area that is approximately 1.5 mm x 1.5 mm. The particles 182 preferably have a thickness of about 2 mm (the thickness of the absorbent foam material). Absorbent material 182 may optionally have ungrooved strips 184 remaining therein due to the presence of channels 170 in the second pair of rollers 162. Again, the nonwoven carrier web 124 is not grooved, but has another pattern formed in the same. The total pattern formed therein resembles a grid with a combination of impressions created by the first and second groups of rollers 132 and 162. The upper sheet of apertured film 156, if fed into the process between the first and second rollers. groups of rollers, will have a pattern formed therein that resembles that of the second group of rollers 162. Figure 45 shows the mixed band 120 that has been fed through the apparatus shown in Figure 44. As discussed above, A sheet of the apertured film upper sheet material 156 preferably has been attached to the mixed web 120. FIG. 45 shows that the sheet of the apertured film upper sheet material 156 is preferably of a size that is approximately equal to the width, but greater than, the individual lengths than those that were cut in the mixed band 120. The apertured film 156 extends beyond the ends of the film. e the individual lengths of the mixed web material so that the tube of the absorbent material, once formed, can be more easily attached to the sanitary napkin when the ends thereof are fused to the base pad of the sanitary napkin. It should be understood that in Figure 45, the pattern printed on the nonwoven material 124 by the first and second roller groups has been omitted or simplified. In addition, the absorbent foam material 122 is shown as comprising only particles 182 for simplicity (i.e. no strips or slots left in incompatible material 122 are shown). Said embodiment can be created by providing the rollers on the first and second groups of rollers 162 with continuous teeth and omitting the channels 146, 170 and 178 between the teeth. It should be understood that the drawings illustrate a particularly preferred form for forming the particulate absorbent foam material. The method for making the sanitary napkin of the present invention is not limited to a process that involves forming the absorbent foam material into particles in the manner shown in the drawings. (3) Folding the Tube to Form the Mixed Band The next step to make the tube of absorbent material for the sanitary towel shown in Figure 1, is to fold or fold the combination of the mixed band 120 and the sheet of material of the sheet film top with opening 15 (the mixed band forming tube) 188. Figure 45 shows the longitudinally oriented fold lines, F, around which the longitudinal side margins 190 of the mixed band forming tube 188 will initially be bent. Figure 46 shows the mixed band forming tube 188 after the side margins 190 thereof have been folded along the fold lines F in a first fold operation to form a "C" shaped bent structure. Figure 47 shows the mixed band forming tube 188 after it has been bent in a second bending operation. As shown in Figure 47, the mixed band forming tube 188 has been folded along its longitudinal center line L3. As a result, the previously folded longitudinal side margins 190 remain adjacent to each other, and the longitudinal side margins 190 of the mixed band forming tube 188 are placed within the mixed band forming bent tube 188. As shown in Figure 47, the folded longitudinal side margins 190 lie adjacent to the longitudinal center line L3 of the mixed band forming tube 188. The mixed band forming tube 188 shown in Figure 47 is now ready to be attached and configured to the desired three-dimensionally formed structure . (4) Union and Configuration of the Mixed Band Forming Tube In the process shown in the drawings, in order to join and form the absorbent foam material, in the most general sense, at least the portions of the band of material that they have the second higher bonding capacity (the non-woven) 124 placed on the outside of the absorbent foam material 122 (the incompatible material). The cross section of the actual structure being joined (as shown in Figure 50) is a little more complicated than that, but for the purposes of the present description, the relationship generally described above (with the web of material having the second greater bonding capacity positioned outside the band of the absorbent foam material) is preferably present. The mixed band forming bent tube 188 is then joined with one or more joints 54. The joints 54 penetrate the incompatible absorbent foam material 122, and join one portion of the non-woven web 124 to another portion of the non-woven web 124 on the opposite side of the absorbent foam material 122. The number of joints 54 and the placement of the joints depends on the desired configuration for the tube of absorbent material 22. To make the particular tube of absorbent material shown in Figures 1 and 2, from two to 5 joints 54 are preferably used. In the embodiment shown in the drawings (see Figure 49), three joints 54 are used. The joints 54 are preferably spaced approximately 4.4 cm apart, and approximately 17 mm of the fold made along the longitudinal center line L3 of the mixed band forming tube 188. Although the sanitary napkin of the present invention and the method for making the same may use unions of any suitable size, the joint sizes which have been found to be suitable have a circular planar view configuration with a diameter of approximately 3 mm and an area of approximately 8 mm2. Bonding can be achieved using heat and / or pressure, or ultrasonic bonding. Suitable techniques for bonding with heat and / or pressure are described in more detail below. Suitable techniques for ultrasonic bonding are described in U.S. Patent 4,430,148 to Procter & Gamble, entitled "Ultrasonic Bonding Process" (Process of Ultrasonic Union) issued to Schaefer on February 7, 1984, and U.S. Patent 4,823,783 entitled "Adhesive-Free Bonding of Continuously Moving Webs to Form Laminate Web and Products Cut Therefrom" (Adherent Union of Bands Continuously in Motion to Form a Laminate Band and Cut Out Products thereof) issued. Willhite Jr. et al. on April 25, 1989. Figure 48 shows a preferred embodiment wherein joining is achieved by dynamically joining portions of the second web of material (non-woven cover) 124 and / or the topsheet material of the web. apertured film 156 on each side of the absorbent material 122 together using pressure and optionally heat. Many of the principles described for this process are similar to those that could be applied if ultrasonic bonding were used. In the embodiment shown, at least one of the materials to be joined (the nonwoven cover or the apertured film top sheet material) preferably comprises a thermoplastic material. (It should be noted that, for simplicity, the joint will be expressed below the terms of joining portions of the non-woven cover 124 together, although portions of the upper sheet material of apertured film may be similarly joined in the process) . As shown in Figure 48, a first portion 124A of the cover material 124 is preferably joined through the mixed band forming tube 188 to a second portion 124B of the covering material. The apparatus used to join the mixed band forming tube 188 preferably comprises a pair of cylindrical rollers 110 and 112. Preferably, at least one of the rollers, the roller 110, has a relief pattern on its surface. The patterned roller 110 is configured to have a circular cylindrical surface 115, and a plurality of protrusions or pattern elements or "pattern element segments" 116, which extend outwardly from the surface 115. The relief pattern It can be in any suitable configuration. It can be linear, curvilinear, or it can be composed of linear segments and curvilinear segments. The relief pattern can be continuous or intermittent. The relief pattern can define an unlimited number of patterns and another type of design. For example, you can define geometric shapes, arrows, words, etc. The land surfaces 118 on the pattern element segments can also be provided in a wide variety of possible ways. Suitable shapes for land surfaces 118 include, but are not limited to, oval and circular. The relief pattern, in the embodiment of the apparatus shown, comprises a plurality of separate pattern elements 116 having circular terrestrial surfaces 118. in the embodiment of the method shown in Figure 48, the pattern elements 118 are arranged in a linear configuration intermittent. The pattern elements 116 preferably have side walls 119 that are not perpendicular to the surface of the cylindrical roller. Preferably, the side walls 119 of the pattern elements 116 form an angle of between about 60-70 ° with the surface of the cylindrical roller. The modification of the orientation of the side walls of the pattern elements 116 is necessary due to the thickness of the absorbent material between the materials being joined, and the desire to prevent rupture of the cover material 124. The other roller 112, serves as an anvil member and, in this manner, may be referred to as an anvil roll 112. The pattern roller 110 and the anvil roll 112 define a pressure deflected nozzle 114 therebetween. Preferably, the anvil roll 112 is of a smooth surface. In other embodiments, however, both the roller 110 and the 112 may have a relief pattern and / or pattern elements thereon. If this is the case, the pattern elements on the opposed rolls will preferably be aligned with each other to compress the materials that will be bonded together. The pattern roller 110 and the anvil roller 112 preferably deviate toward each other with a predetermined pattern element load of about 140 MPa to about 1400 MPa. The pattern roller 110 and the anvil roller 112 preferably are directed in the same direction at different speeds, so that there is a surface velocity differential between them. The surface velocity differential preferably has a magnitude of about 2 to about 40% of the roller having the lowest surface velocity, most preferably between about 2 and about 20%. The anvil roller is preferably operated at a surface speed that is greater than the surface speed of the pattern roller 110. A method for dynamically joining a sheet between a pair of rolls having a surface velocity differential between them is described in more detail in U.S. Patent 4,854,984 issued to Ball et al. on August 8, 1989. The method may further comprise the step of heating one or both rollers. If the rolls are heated, they are preferably heated to a surface temperature which is a predetermined number of degrees below the melting temperature of the thermoplastic material in the cover material 124. It is also possible, at high line speeds, to that the union occurs at a speed differential of 0 (that is, with the nozzle defining rollers having equal surface velocities). The bonding process shown in the drawings penetrates through the mixed band forming tube 188 and autogenously joins the first portion 124A of the nonwoven cover material to the second portion 124B of the cover material 124. The term "autogenous", as used herein, refers to the joint without a third material such as stitching or adhesives. The method described herein, however, is not intended to be limited to one that excludes the stitches or the adhesive increase of said autogenous bond. Figure 50 shows that the joint compresses, or very preferably, displaces the absorbent foam material in localized areas, where joints 54 are formed. This isolates a three-dimensionally formed portion 100 of the foam material particle web from the remainder of the web. the particle strip of the absorbent foam material (generally referred to as reference number 102) and forming the insulated portion 5 as well as the entire mixed band forming tube 188) in a different form. In the embodiment shown in the drawings, the joint forms the mixed band forming tube 188 in a profile shape wherein the portion of the composite band 188 that will form the upper part of the absorbent tube on the finished product is given a width narrower. Preferably, as shown in Figure 1, the portion of the mixed web 188 that will form the upper part of the absorbent tube in the finished product defines a flange projecting perpendicularly from the top of the remainder of the absorbent tube (and the remainder of the absorber tube). the sanitary towel). As shown in Figures 1, 49 and 50, the joint also provides the mixed band 188 with tucked regions 56, where the mixed band forming tube 188 is placed around the bonding sites 54. The joints 54 can be placed in a virtually unlimited number of patterns to create products that have a virtually limited number of possible geometric shapes. The joint patterns can also be used to add structural stability as well as tube configuration of absorbent material by adding a degree of rigidity to the product along the line that passes through the joints. This line can be rectilinear, curvilinear or partially rectilinear or partially rectilinear and partially curvilinear. The joining method described herein can also be used in the manufacture of the line running at high speeds (eg, 213.3-304.8 meters per minute) and is not limited to particular patterns, such as sewing processes. (Of course, in less preferred embodiments sewing processes or other processes may be used to maintain the tube of absorbent material in the desired cross-sectional configuration). Figure 50 also shows that the joints 54 penetrate the foam material particle layer 122. The joints 54 are formed between the opposite portions of the nonwoven web 124 having the second highest bonding capacity that are placed outside of the web. the particles of the foam material 122. The attachment mechanism preferably slides through or displaces the particles of foam material 122., so that there is a clear trajectory for the materials that can be joined so that they join together. Preferably, very little (if any) of the foam material is left in the binding sites. Another advantage of the grooving or formation of the absorbent material into particulate material, especially where the grooved or particulate material is adhered to a carrier web, is that the method used to form the grooved or particulate material can be used to provide a Clear continuous path for the joints to penetrate through the absorbent material. Methods for shredding the absorbent material which merely crumbs the absorbent material and blows it to a serrated tube through air, will result in a random distribution of the shredded particles. Said method is less preferred since it will not form the clear trajectory for the connection described here. After the joining process, the bonded band forming tube 188 preferably is cut to form a plurality of individual tubes of absorbent material 22. The apparatus used to cut the joined mixed band forming tube 188 is also shown in Figure 48. the apparatus comprises a pair of rollers 192 and 194. One of the rollers, the roller 192 has at least 1 and preferably a plurality of knife elements 198 on its surface. The blade elements 198 are preferably configured to make a plurality of generally transverse direction cuts in the mixed band forming tube 188. The other roller 194 serves as an anvil member, and thus can be referred to as an anvil roller. 194. Blade roller 192 and roller 194 also define a nozzle 196 therebetween. After the cutting step, the individual tubes of absorbent material 22 are transported on a conveyor 200 to join base pads 24 to form the sanitary napkin 20 of the present invention. Other variations of the method described herein are also possible. For example, it should be understood that the method for folding and joining described herein is not limited to being used in the manufacture of a tube of three-dimensionally formed absorbent material for a sanitary composite pad. This method can be used more widely to make other types of absorbent articles three-dimensionally formed from generally flat materials. The material or laminate of shipping materials can be folded and joined at those sites where a portion of the bent strip is desired to assume a three-dimensional shape, and can be left unfolded and unbonded at those locations where it is desirable that a portion of the material remains flatter. It is also possible to hold a hillock or tube of absorbent material in place without fully bonding through the absorbent material. For example, Figures 51 and 52 show a three-dimensionally sanitary napkin 5120 with a raised central portion 5122. The sanitary napkin 5120 comprises a topsheet 5170, a backsheet 5172 and an absorbent core 5174 comprising at least some synthetic fibers . The synthetic fibers provide the absorbent core 5174 with improved integrity and provide a bondable material for joining the topsheet and / or the backsheet to the absorbent core. In a version of the embodiment shown in Figures 51 and 52, the absorbent core 5174 comprises between 10-20% of homogeneously blended synthetic fibers with air filter and absorbent gelling material. Top sheet 5170 preferably comprises a top sheet of open film DRI-WEAVE, and back sheet 5172 preferably comprises a polyethylene film. The synthetic fibers in the absorbent core 5174 preferably comprise polyethylene to provide similar melting point properties to the topsheet and the backsheet. Suitable commercially available synthetic fibers are PULPEX synthetic fibers. In the modality shown in Figure 52, both the topsheet 5170 and the backsheet 5172 are bonded together through the absorbent core 5174. However, in other embodiments, the absorbent core 5174 can be heated (such as by passing the sanitary napkin through a tunnel heat) to create a matrix of thermally bonded synthetic fibers where it is possible to print bonding patterns to provide the sanitary napkin with a three dimensional shape without joining the topsheet to the backsheet in the region of the joints. The embodiment shown in Figures 51 and 52 can be made using an ultrasonic data pattern in an hourglass shape with a depressed center (i.e., a cavity) to create the desired raised hillock in the center of the sanitary napkin. The ultrasonic die and the anvil roller can create heat and pressure to "weld" the top sheet and the backing sheet to the core area of the curvilinear channels. In other embodiments, less pressure may be used to weld only the topsheet 5170 to the absorbent core 5174. Said embodiments rely on the synthetic fibers in the absorbent structure to maintain the shape of the core. The hourglass shape for the ultrasonic die can be used to provide a better fit in the crotch area. The finished product is capable of using the pressure created by the user's legs to actively "push" the center of the sanitary napkin into a closer contact with the user's body. Mixing the synthetic fibers with any of the absorbent materials described herein in this manner may allow three-dimensionally formed absorbent structures to be provided without complete bonding through the absorbent structure.

B. Attaching the Absorbent Material Tube to the Base Pad to Form the Composed Sanitary Towel Figure 1 shows a sanitary composite pad 20 having the material tube 22 on its side facing the body. To form the composite sanitary napkin 20, a sanitary napkin can serve as the pantiprotector (or "base pad") 24 and the tube of absorbent material wrapped by a topsheet 40 (or "primary menstrual pad") 22 is placed over the upper part of the sanitary napkin 20 and attached thereto. Preferred sanitary napkins suitable for use as the base pad 24 are as described above. In a particularly preferred embodiment, the joints 54 are located in the portion of the tube that will lie in the central region 32 of the sanitary napkin 20. In this preferred embodiment, it will form a tube having a three-lobed transverse configuration previously described together with Figure 2. In the preferred embodiment shown in Figure 2, the portions 62 and 64 of the tube 22 that will lie in the end regions 28 and 30 of the sanitary napkin are preferably flattened and bonded to the base pad 24. The union of the The tube 22 to the base pad 24 is preferably achieved through joining extensions 158 of the topsheet material at the ends of the tube to the base pad 24. In some preferred embodiments of said composite towel, there may also be a bond to the base pad 24. the base pad 24 between the ends of the tube of absorbent material 22 and the base pad 24. The tube of the sanitary pad composed can s It is attached to the base pad between its ends through any suitable joining means, such as through adhesives. The method for making the tube of absorbent material three-dimensionally formed here described provides numerous advantages. The method of the present invention involves very few steps and significantly less additional equipment, and does not require a supply system that uses compressed air or a closed receptacle to contain the particulate material. In addition, since the particles are placed in a sheet structure, and are not blown or transferred from a supply system, the result is a significant improvement in the control of particle distribution. That is, the particles can be placed in precise places within the tube of absorbent material. The method of the present invention also eliminates the need to remeasure (or measure) the amount of particulate material delivered to the tube of absorbent material. The method of the present invention also provides the ability to maintain the characteristics of more than one layer of absorbent material relative to the other layers. For example, there may be two layers (or more) of absorbent material, such as absorbent foam, with different characteristics eg, pore size, hydrophilic character, etc.). For example, the uppermost foam layer may have a larger pore size than the lower foam layer (s) to establish a capillary gradient from the outer portions of the tube of absorbent material toward the inner portions of the tube of absorbent material. The method of the present invention is capable of forming one or more of these layers of foam material into strips or particulate material, while keeping the strips of foam particles in their original vertical orientation. This preserves the desired relationship, unlike the previous processes involving air supply system. The above processes can provide a random mix of different particles rather. In addition, the method for forming the absorbent material in a particulate material described herein provides numerous other advantages. The method described here can be used to provide the top sheet with a degree of capacity extension due to the formation of a network that can be stretched from regions in it through the pattern rollers. The formation of a network region that can be stretched in a material to provide the same with extension capacity is discussed in greater detail in the Chappell patent and others. The method of the present invention can also be used to provide the top sheet with additional softness due to the printing of the pattern surfaces thereon. The method described herein can also be used to provide the topsheet with increased flexibility due to the plurality of additional bending axes imparted in the topsheet by the ridges and valleys on the pattern rolls. further, the method described herein can provide the advantage of improving the integrity between the layers of the mixed band. Furthermore, using this method, the absorbent articles can be very easily configured through conventional bending devices, and the shapes and / or dimensions of the tube of absorbent material can be varied (for example, if it is necessary to adapt the consumer's preferences in different geographies) by changing the tool instead of changing the basic process. In other embodiments, the different aspects of any of the modalities described herein can be combined to produce other modalities. For example, a sanitary napkin having a tube of absorbent material in a three-lobe transverse configuration may be provided as shown in Figures 1 and 2, but which is fully integrated into the base pad, and forms part of the absorbent core. of the base pad similarly to the mushroom-shaped structure shown in Figures 26-28. An example of such a sanitary napkin may be presenting as a sheet disposed from the top towards the bottom of: the top sheet material (eg, film with DRI-WEAVE openings), a layer of a secondary top sheet material (eg example, non-woven material P-9), absorbent foam material, and another layer of secondary topsheet material. The longitudinal central region of the thus formed sheet is preferably subjected to the SELFing process, but the laterally outward portions are preferably not SELFed. The SELFed portion will form an elevated absorbent hillock with softer, body-shaping properties. The entire sheet is then bent and similarly joined to the three-lobed structure shown in Figure 2, only the longitudinal side margins of the bent band do not extend upward toward the central lobe 34 and a separate upper sheet is not provided for tube thus formed. Rather, the longitudinal side margins extend upward from the bonding area, and bend downwardly and laterally outwardly as in the case of a mushroom-shaped structure shown in Figure 27 to form the absorbent core of the cushion. base. A backing sheet can then be added and the folded and bonded sheet can be cut into the desired shape to complete the formation of the sanitary napkin. The descriptions of all patents, patent applications (and any patents issued therefrom, as well as any corresponding published foreign patent applications), and publications mentioned throughout this description are hereby incorporated by reference in their entirety. However, it is expressly not admitted that any of the documents incorporated herein by reference teach or describe the present invention. Although particular embodiments of the present invention have been illustrated and described, it may be obvious to those skilled in the art that other changes and modifications may be made without departing from the spirit and scope of the invention.

Claims (7)

1. - A method for individually packaging a three-dimensionally shaped absorbent article, said method characterized in that it comprises the steps of: (a) providing a three-dimensionally shaped absorbent article, said three-dimensionally configured absorbent article having a longitudinal centerline, a transverse centerline, a height and a pair of longitudinal sides, a body surface, an outer surface, and one or more indentations on the longitudinal sides that provide bending axes to bend the absorbent article; (b) providing a wrapper for individually packing the absorbent article and placing the wrapper adjacent the outer surface of the absorbent article; and (c) folding the three-dimensionally shaped absorbent article and wrapping around at least one transverse axis, wherein the transverse axis is located in the region adjacent to or including at least one of the indentations on the longitudinal sides of the absorbent article.

2. The method according to claim 1, wherein the indentations comprise fusion junctions.

3. A method for individually packaging a sanitary napkin, said method characterized in that it comprises the steps of: (a) providing a mixed sanitary napkin, the sanitary napkin having a main longitudinal center line and a main transverse center line, and comprising a base pad having a body surface and a garment surface, said tube of absorbent material attached to the body surface of the base pad, wherein: (i) the tube of absorbent material has a base, a vertex, and sides, said tube of absorbent material having a caliper greater than the caliper of the base pad and two or more fusion joints on the sides of said tube of absorbent material between the base and the apex of said tube of material absorbent, said fusion joints providing bending axes to bend the tube of absorbent material; (ii) said base pad has an adhesive fastener on the garment surface; and (b) providing a removable wrap to cover the adhesive fastener on the garment surface of the base pad; and (c) folding the sanitary napkin and the peel wrap around at least one transverse axis, wherein the transverse axis is located in the region adjacent to or including at least one of the melting joints in the tube of absorbent material.

4. The method according to claim 3, wherein the step (c) of folding the sanitary napkin and the peelable wrap further comprises compressing the tube of absorbent material before bending the sanitary napkin and the peel wrap.

5. The method according to claim 4, wherein the compression is mainly applied along the main longitudinal center line and the base pad remains substantially uncompressed.

6. The method according to claim 4, wherein the tube of absorbent material comprises a compressible and elastic absorbent material having a maximum uncompressed caliber, the one where after compression said absorbent material recovers at least 50% of its maximum size without compression.

7. The method according to claim 6, wherein the elastic absorbent material comprises a foam absorbent material.