MXPA02001871A

MXPA02001871A - Absorbent article having vertically orientated absorbent members and method for forming.

Info

Publication number: MXPA02001871A
Application number: MXPA02001871A
Authority: MX
Inventors: Dipalma Joseph
Original assignee: Kimberly Clark Co
Priority date: 1999-09-15
Filing date: 2000-08-28
Publication date: 2002-08-12
Also published as: KR20020027650A; BR0013970A; DE10085036T1; AR025649A1; GB2371232A; GB0208623D0; GB2371232B; WO2001019307A3; WO2001019307A2; CN1390117A; AU2612801A

Abstract

Absorbent pad assemblies and articles are provided which include adjacent noncontinuous vertically orientated absorbent members, horizontally displaced relative to each other along the entire vertical heights thereof and forming a vertically disposed surface interface therebetween. Also provided is a method for forming an absorbent structure wherein absorbent members are adjacently disposed and orientated such as to have a specifically desired ratio of horizontal width to vertical height.

Description

ABSORBENT ARTICLE THAT HAS ABSORBENT MEMBERS VERTICALLY ORIENTED AND METHOD FOR THEIR TRAINING FIELD OF THE INVENTION This invention relates generally to absorbent articles for absorbing body fluids and exudates. More particularly, the present invention relates to absorbent pad assemblies and associated absorbent articles that have improved fluid flow prevention and / or control prevention as well as to a method for forming same.

BACKGROUND OF THE INVENTION A wide variety of types of structures are known in the art for use in absorbent articles or as absorbent articles, particularly disposable absorbent articles, used to collect various fluids and exudates from the body. Commercial absorbent articles include diapers, adult incontinence products, sanitary napkins and bandages. Disposable products of this type generally comprise components for receiving, absorbing and retaining fluids. Typically, the components of such articles include a liquid permeable top sheet, an absorbent core and a liquid impermeable bottom sheet.

The components of the typical absorbent articles are commonly placed in layers or arranged in a horizontal shape with a main flat surface facing the fluid absorption area, for example, the body of the user. In such articles, the nature or constitution of fluid communication therethrough can and will typically change as the fluid passes through the stratum or horizontal strata. Therefore, such absorbent articles may experience an undesirable horizontal dependence between the components. In addition, the fibers which customarily constitute the absorbent core are often randomly oriented with fibers within a mat in a neighboring side arrangement so that fluid absorption is typically transmitted in a radial pattern or shape.

One of the main objectives in the development of absorbent articles is the increase, improvement or maximum utilization of the absorbent capacity of the article. In general, products of the type described above will typically distribute liquids deposited on the topsheet in a circular pattern. Since such structures generally have a length exceeding their width, such a liquid distribution can undesirably result in fluids, eg, exudates, reaching the longitudinal side edges of the absorbent article before the desirable utilization of the absorbent capacity in the regions. end of article ^^? ... * - A, í m J? .4μ * f * í - ~ .-- »-» - '~ - * - - - ~ «^ * r, ..- A ... é a .. .J absorbent. As will be appreciated, such an occurrence may undesirably increase the possibility or likelihood of runoff from the sides of the article despite the availability of unused or underutilized absorbent capacity in the end regions of the absorbent article.

In addition, such absorbent articles can and should be subjected to a wide range of conditions and applications such as those that are due to factors inherent or related to the environment in which the article is used. Therefore, fluids and exudates which may require being absorbed by them may vary in properties or parameters such as the inclusive flow rate as well as the shape, phase or composition. For example, the exudates may be multiphasic and heterogeneous, such as in the case of menstrual fluids which may include red blood cells, mucin, plasma and tissue debris, for example.

Sanitary napkins (also referred to as catamenial pads), women's pads, night pads, panty liners, and panty shields are designed to be worn by a woman to absorb menstrual fluids and other body fluids discharged before, during and after a menstrual period. Sanitary towels are external devices which are designed to be aligned near the pudendal region of a human body I r ** -, -r-j- lü,. "I" mat '-Ea._ a.il luiilil l Hit, lll I I Tülf ^? Ai átálltg ^? ^ T? a. ^? ^? ¡^ li? AA and are generally held in position by being attached adhesively or mechanically to an undergarment. Sanitary napkins also typically differ from panty liners and panty shields in several notable ways. Sanitary napkins are generally larger in size and have a defined three-dimensional configuration, are thicker in gauge and have a greater fluid capacity than panty liners or panty shields.

In view of the desire to provide increased comfort to the user and to minimize the appearance of the presence of such absorbent articles there is a continued demand and a need for smaller and less bulky absorbent articles. Therefore, there is a need and a demand for absorbent pad assemblies and improved absorbent articles so that they can result in a more complete use of the absorbent capacity thereof and so that they can more effectively and efficiently to a possibly wide range of operating and operating conditions to which such assemblies and articles may be exposed. More particularly, there is a need and a demand for sets of absorbent pads and absorbent articles which have improved control or handling of fluid flow in association therewith. £. iJk-mt? * i. ^ ,. 1 a *,. m * *. mm .., *,. * m,. m ^ ***. . ". ^. " to . - ^ *. **? , ti..i.

SYNTHESIS OF THE INVENTION A general object of the invention is to provide an improved absorbent pad assembly and an absorbent article. Another general object of the invention is to provide a method for forming absorbent structures such as either or both an absorbent article or an absorbent pad assembly.

A more specific objective of the invention is to overcome one or more of the problems described above.

A general object of the invention can be achieved, at least in part, through a specific absorbent pad assembly. According to a preferred embodiment, the absorbent pad assembly includes at least the first and second adjacent non-continuous vertically oriented absorbent members. Each of the first and second absorbent members have a vertical height. The first and second absorbent members are horizontally displaced one relative to the other along the full vertical heights thereof and form a surface interface positioned vertically therebetween.

The prior art generally fails to provide absorbent pad assemblies and absorbent articles which make full or complete use of the absorbent capacity thereof as may be desirable. The prior art also generally fails to provide absorbent pad assemblies and absorbent articles which can respond to a possibly wide range of operating and operating conditions to which such assemblies and articles can be exposed and do so in an effective and efficient manner. how it can be desired.

The invention further comprises a specific absorbent article. According to a preferred embodiment of the invention, such an absorbent article includes an absorbent pad assembly. The absorbent pad assembly includes at least the first, second and third generally planar absorbent members. Each has a vertical height and wherein at least the first and second absorbent members comprise materials of different chemical compositions. The first and second absorbent members are displaced one relative to the other along the full vertical heights thereof and form a first surface interface positioned vertically therebetween. The second and third absorbent members are displaced horizontally in relation to each other along the full vertical heights thereof and form a second surface area placed vertically between them.

The invention further still comprises, according to another embodiment of the invention, an absorbent article having a contact surface. The absorbent article includes a pad assembly. The pad assembly includes at least the first and second adjacent non-continuous absorbent members of a different absorbency. The first and second absorbent members are generally placed perpendicularly in relation to the contact surface and form a surface interface between them also generally placed perpendicularly in relation to the contact surface.

Another aspect of the invention relates to specific methods for forming such absorbent structures and the like. According to one embodiment, one such method involves placing adjacent at least the first and second absorbent members and orienting adjacent first and second adjacent adjacent members for each to have a horizontal width to vertical height ratio of no more of about 10: 1.

According to another embodiment, a method for forming an absorbent pad assembly is provided. Such a method involves horizontally layering at least the first and second absorbent members and vertically bursting the first and second absorbent members horizontally in layers.

According to another embodiment, a method is provided for improving fluid handling by means of a 10 absorbent article which includes a liquid permeable cover, a liquid impermeable bottom sheet and an absorbent pad assembly positioned between the cover and the bottom sheet. The method involves the use of an absorbent pad assembly including at least the members 15 vertically oriented non-continuous and adjacent first and second absorbers, each of the first and second absorbent members has a vertical height with the first and second absorbent members placed horizontally relative to each other along the full vertical heights thereof 20 and that form a surface interface placed vertically therebetween. As described in more detail below, a particular form of such an absorbent article is a sanitary napkin. 25 As used here, references to the "absorbent articles" should be understood as referring to *? JaLaiaJ, such products as diapers, sanitary napkins, training pants, incontinent garments, night pads, panty liners, under arm shields and the like which will be used to absorb body fluids and exudates, such as urine, menstrual fluids, blood, sweat and other excrement discharged by the body.

In addition, the references given herein to absorbent members as being "vertically oriented" should be understood to refer to the general arrangement of the member and are in general reference in relation to the contact surface of the body or face of the absorbent article itself. In general, the vertically oriented absorbent members should be understood as having a horizontal width ratio at a vertical height of no more than about 10: 1, preferably no more than about 5: 1 and more preferably about 1: 1. or less.

The references given here to the adjacent absorbent members as being "non-continuous" should be understood as referring to such adjacent absorbent members as forming or having a surface interface therebetween. As will be appreciated, such surface interfacing can, in practice, serve to impair, prevent or prevent passage of fluid between or from one to another of the adjacent absorbent members. As will be appreciated and as described in TO **. l. llmml **. When the greater detail is below, the adjacent absorbent members will preferably differ in one or more properties or characteristics such as the chemical composition or construction such as the orientation of the composition. fiber or thickness, for example. Other effective properties or characteristics by virtue of which the adjacent absorbent members can be differentiated will be apparent to those skilled in the art and guided by the teachings herein provided.

The references given here to the adjacent absorbent members as forming a "surface interface" therebetween should be understood as referring to the formation between the adjacent members of a surface on which said adjacent members make contact. 15 or are in proximity to each other.

The references given here to the "contact surface" shall be understood as referring to that surface of the absorbent member, of the absorbent pad, 20 of the article or the like with which the fluid to be absorbed initially makes contact.

Other objects and advantages will be apparent to those skilled in the art from the following detailed description taken in conjunction with the appended claims and drawings. . r? «m .: i, 1 .i r BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic perspective view of an absorbent article having a pad assembly according to a preferred embodiment of the invention.

Figure 2 is a perspective view in partial and schematic section of the absorbent article shown in Figure 1.

Figure 3 is a simplified and schematic sectional side view of the absorbent article shown in Figures 1 and 2.

Figures 4-5 are fragmentary and simplified top views of the absorbent articles according to the alternate embodiments of the invention.

Figures 6-10 are simplified alternate side sectional views of the absorbent articles taken essentially along the lines A-A and B-B of Figures 4 and 5, respectively, and viewed in the direction of the arrows.

FIGS. 11 and 12 are simplified fragmentary top views of the absorbent articles according to still further alternate embodiments of the invention.

Figure 13 is a simplified sectional side view of an absorbent article taken essentially along lines C-C and D-D of Figures 11 and 12, respectively, and viewed in the direction of the arrows. 10 DETAILED DESCRIPTION OF CURRENTLY PREFERRED INCORPORATIONS The present invention, as described in more detail below, provides an absorbent pad assembly 15 and an improved absorbent article as well as a method for forming such absorbent products.

Referring initially to Figures 1-3, there is illustrated an absorbent article generally designated with the 20 reference number 30, according to an embodiment of the invention and whose article is capable of absorbing body fluid. The absorbent article can be a diaper, a training underpants, a sanitary napkin, a panty liner, a night pad, an incontinence garment, 25 a shield under the arm, or another type of absorbent product capable of absorbing one or more of the body fluids such as urine, menstrual fluids, blood, sweat, stool or the like. As will be appreciated, such an absorbent article will typically be disposable in nature. Although the absorbent article 30 will be described herein in terms of a female care product such as a sanitary napkin, it should be understood that the broadest practice of the invention is not necessarily limited and that the invention can, if desired , to be practiced in or associated with other types or forms of absorbent articles as identified above.

The absorbent article 30 comprises a cover or upper sheet generally permeable to liquid 32 on the side-to-body surface of the article, a separator or lower sheet generally impermeable to liquid 34 on the opposite side of the article and a core absorber 35 placed and enclosed between them.

It will be appreciated that absorbent articles such as women's care products such as sanitary napkins can typically include usual or standard features such as those relating to the placement or putting of the article when in use. For example, certain sanitary napkin designs incorporate side flaps, some of which are referred to as "wings" such as may be useful in preventing the flow of fluid from the sides of the towel. * - € d a Another example of such a feature is the inclusion or the presence of an adhesive on or around the front region face of the bottom sheet garment. Such an adhesive surface of the article may be covered by a release paper or the like, as is known in the art, before use such as when in a packaged state. As such features are standard or common, as is well known to those skilled in the art and are not part of the larger invention, they will not be shown or described in greater detail here.

The cover 32 is generally designed to make contact with the wearer's body and generally forms the contact surface of the absorbent article 30. In practice, the topsheet 32 can be constructed of a woven or non-woven material, Synthetic or natural materials and desirably should be easily penetrated by the body fluid. Such suitable materials include carded and bonded fabrics of polyester, polypropylene, polyethylene, nylon or other heat-bondable fibers. Other polyolefins, such as polypropylene and polyethylene copolymers, linear low density polyethylene, finely perforated film fabrics and the network material also work well. The topsheet 32 can also be constructed of a thermoplastic film which contains openings and is flanked on one or both sides by a nonwoven material. Such incorporation can desirably have a relatively smooth feel against a user's thighs while allowing the body fluid to pass through it quickly.

The separator or lower sheet 34 is generally impermeable to liquid and is designed to face the inner face, for example, the crotch portion of an undergarment (not shown). The bottom sheet 34 may desirably be designed to allow passage of air or steam towards 10 outside the absorbent article 30 while preventing or blocking the passage of fluids through it. As will be appreciated, the lower sheet 34 can be made of any suitable material capable of providing or having the properties or features identified above. For example, Suitable materials may include a micro-etched polymer film such as polyethylene or polypropylene.

As will be appreciated, the upper sheet 32 and the lower sheet 34 can be placed coextensive, in a contact of 20 face to face around or near the absorbent core 35. Furthermore, the topsheet 32 has a periphery 32a and the lower sheet 34 has a periphery 34a which are desirably joined or sealed together by the use of an adhesive, by means of ultrasonics sealing with heat or other techniques 25 properly selected such as are known to those skilled in the art.

.A? At, l? K - .. j Efe * • 3 * "", '16 The absorbent core 35 is formed at least in part by an absorbent pad assembly 36. As shown in Figures 2 and 3 , the absorbent pad assembly is a three-dimensional structure having a horizontal axis XX, a vertical axis ZZ and an axis of length Y. The absorbent pad assembly 36 includes the vertically oriented non-continuous and adjacent absorbent members 40, 42, 44 , 46, 48, 50 and 52, respectively In practice, the absorbent pad assemblies according to the The invention will typically include at least two and, preferably, at least three, of such adjacent vertically oriented non-continuous absorbent members. As will be appreciated, the specific number or nature of the absorbent members included within the pad assembly The absorbent according to the invention can generally be selected by one skilled in the art and can be guided by the teachings given herein in order to satisfy the required or desired performance criteria of the particular application to which the assembly under consideration is directed. As shown, the adjacent absorbent members 40 and 42 form a vertically positioned surface interface 41 therebetween. Similarly the adjacent absorbent members 42 and 44 form a surface interface 25 positioned vertically therebetween, the adjacent absorbent members 44 and 46 form a vertically positioned surface interlock 45 therebetween, the adjacent absorbent members 46 and 48 form a vertically placed surface interface 47 therebetween, the adjacent absorbent members. 48 and 50 form a vertically placed surface inter-face 49 therebetween, and the adjacent absorbent members 50 and 52 form a surface interlock positioned vertically therebetween 51. As will be appreciated, the surface interleaves 41, 43, 45, 47 , 49 and 51 are each generally placed perpendicular in relation to the contact surface of the absorbent article 30.

As shown, the adjacent absorbent members are displaced horizontally in relation to one another along the full vertical heights thereof. That is, adjacent absorbent members generally have no parts that have the same placement on the X-X axis. For example, no part of the absorbent member 40 lies under or has the same X-X axis placement as a part of the adjacent absorbent member 42.

Each of the absorbent members 40, 42, 44, 46, 48, 50 and 52 is generally planar and is positioned perpendicularly in relation to the contact surface of the absorbent article 30. The absorbent members each have a vertical height (h), a horizontal width (w) and a longitudinal extension (1). As will be appreciated, the height, width and ** Specific lengths of the used absorbent members will generally be selected to meet the particular requirements of the application to which such absorbent members are to be applied. The absorbent members 5 used in the practice of the invention will generally have a width in the range of about 0.03 millimeters to no more than about 20 millimeters and a height of about 1 millimeter to about 15 millimeters. In practice, however, the absorbent members used in the invention will typically have 10 a width of no more than about 8 millimeters (for example, in the range of about 0.5 millimeters to about 8 millimeters) and, preferably, will have a width of no more than about 5 millimeters (for example, in the range of about 1 millimeter to about 5 millimeters). According to the invention, the absorbent members are advantageously arranged such as to generally provide a width-to-height ratio much lower than what is normally obtained or carried out in 20 absorbent articles such as sanitary napkins. Such absorbent member arrangements, with significantly lower width-to-height ratios, promote transmission in the Y-Y and Z-Z directions since fluid is more likely to move to fibers in close proximity.

Nearly rather than extending through vertically positioned surface masks formed between the adjacent absorbent members.

In addition, the vertical orientation of the adjacent absorbent members according to the invention allows the design of absorbent pad assemblies and associated absorbent articles which facilitate the use of multiple and selected absorbent materials in close proximity to the fluid absorption area. As will be appreciated by those experts in the art, at least certain absorbent articles, including various women's care products such as sanitary napkins, may be required to function satisfactorily in association with fluids having a variable or wide range of possible or feasible constituents. Thus, the present inventive development of the absorbent pad assemblies and the absorbent articles where possible multiple different absorbent materials can be conveniently placed in close proximity to the fluid absorption area is a significant advance in the art. Also, the absorbent pad and absorbent article assemblies of the invention can advantageously avoid complications such as those relating to horizontal dependence, as described above.

According to a preferred embodiment of the invention, the absorbent members preferably have a i * Am. * jt width to height ratio of less than 1 in order to more fully realize the benefits of the specifically oriented absorbent members of the present absorbent pad assembly and the absorbent article.

Even though the height and width of each of the absorbent members for the absorbent pad assembly 36 are the same, it is understood that the broader practice of the invention is not necessarily limited and that the invention can, if desired, be practiced in conjunction with absorbent members which differ in height, width or both.

Absorbent members for use in the practice of the present invention can be manufactured or formed of various suitable absorbent materials such as are known in the art. For example, the absorbent members selected for use in the practice of the invention may be manufactured or formed of various hydrophilic types of natural or synthetic fibers including cellulose fibers, melt blown fibers treated with surfactant, wood pulp fibers, regenerated cellulose , cotton fibers or a mixture of other fibers.

The construction materials of the absorbent member may include a material described in U.S. Patent No. 4,100,324 and generally IjAmíáü r * * ¡k MA-A > * - * ** * ._ ^ m *. a .. a. to J ^ ja, ». *. | ^ ... r ** .A? ?? Sñ .i- .l? .?. *% known as a coform. The coform is available from Kimberly-Clark Corporation located in Neenah, Wisconsin and is generally a non-woven material made of an air-formed matrix of thermoplastic polymer fibers and a multiplicity of individualized wood pulp fibers, and has a non-woven finish. of cloth. The thermoplastic fiber polymers generally have an average diameter of less than 10 microns with the individualized wood pulp fibers dispersed through the matrix and serve to space these microfibers from each other. Such material can be formed by initially using the primary air stream with the melt blown microfibers and the secondary air stream containing wood pulp fibers and fusing the two streams under turbulent conditions to form an air stream integrated to the long of a forming surface.

In certain embodiments, the use of absorbent materials in the nature of sprouting materials may be desired. Various woven fabrics and non-woven fabrics can be used to construct the materials of emergence. For example, an emergence material may be a nonwoven fabric layer composed of a meltblown fabric or bonded with polyolefin filament yarn. Such layers of non-woven fabric may include conjugated, biconstituent and homopolymer fibers of short or other lengths and mixtures of such - • --- * »- * - *,. *. Í? ? fibers with other types of fibers. The emergence material may also be a carded and bonded fabric or an air-laid fabric composed of natural and / or synthetic fibers. The carded and bonded fabric can, for example, be a carded and bonded fabric, a carded and infrared-bonded fabric or a carded fabric and attached through air. The carded and bonded fabrics may optionally include a mixture or combination of different fibers, and the fiber lengths within a selected fabric may vary from about 3 millimeters to about 60 millimeters.

Examples of particular emergence materials can be found in U.S. Patent No. 5,490,846 issued to Ellis et al. And in U.S. Patent No. 5,364,382 issued to Latimer. The emergence materials can be composed of an essentially hydrophobic material, and the hydrophobic material can be optionally treated with a surfactant or can be processed to impart a desired level of wettability and hydrophilicity.

Another possible suitable absorbent material is the material known as PRISM available from Kimberly-Clark Corporation. A description of the PRISM material is taught in U.S. Patent No. 5,336,552 issued to Strack et al. And the description of that patent is incorporated. by reference here in its entirety. The PRISM is generally the non-woven fabric and comprises extruded multi-component polymer yarns including the first and second polymeric components arranged in essentially different zones across the cross section of the multi-component yarns and extending continuously along the length of the yarn. the threads of multiple components. Preferably, the yarns are continuous filaments which can be formed by spinning techniques. The second component of the yarns constitutes at least a portion of the peripheral surface of the multicomponent yarns continuously along the length of the multicomponent yarns and includes a mixture of a polyolefin and an ethylene alkyl acrylate copolymer . The joints between the multi component threads can be formed by the application of heat. More specifically, the first polymeric component of the multi-component yarns is present in an amount of from about 20 to about 80 percent by weight of the yarns and the second polymer component is present in an amount of from about 80 to about 20 percent by weight of the threads. Preferably, the first polymer component of the multi-component yarns is present in an amount of from about 40 to about 60 percent by weight of the yarns and the second polymer component is present in an amount of from about 60 to about of 40 percent by weight of the threads.

The term "yarn" as used herein refers to an elongate extrudate formed by passing a polymer through a forming orifice such as a matrix. The yarns include fibers, which are discontinuous yarns having a defined length, and filaments, which are continuous yarns of material. The nonwoven fabric of the present invention can be formed of short multiple component fibers. Such short fibers can be carded and bonded to form a non-woven fabric. Preferably, however, the non-woven fabric of the present invention is made of spin-linked and continuous multi-component filaments which are extruded, pulled and placed on a moving forming surface.

The types of non-woven materials that can be used include carded and powder-bonded fabrics, carded and infra-linked fabrics, and carded and bonded fabrics through air. Carded and bonded fabrics with infrared and through air may optionally include a mixture of different fibers and the fiber lengths within a selected fabric fabric may be within the range of about 2.54 cm to 7.62 cm (1.0 to 3.0 inches) and an average volume density of about 0.02 grams per cubic centimeter to about 0.12 grams per cubic centimeter.

Other absorbent materials suitable for use in the practice of the invention may include materials commonly referred to as superabsorbents. The superabsorbents can be in various forms including the particulate and fibrous forms. Known superabsorbent materials include AFA-1 30-53C from Dow Chemical, and W77553 and FAV880A which are commercially available from Stockhausen Company of Greensboro, North Carolina. Stockhausen W77553 is a bulk polymerized polyacrylate with a hydrophobic surface treatment. Stockhausen's FAV880A is a highly cross-linked surface superabsorbent. AFA 130-53C is a suspension polymerized polyacrylate material of 850 to 1400 microns available from the Dow Chemical Company of Midland, Michigan.

The hydrocolloid materials, commonly referred to as superabsorbents, may be in the form of a hydrogel-forming polymer composition which is insoluble in water, lightly cross-linked and partially neutralized. It can be prepared from monomers containing polymerizable and unsaturated acid groups and cross-linked agents. Such superabsorbents are taught in U.S. Patent No. 4,798,603 to Meyers et al., In U.S. Pat. No. 32,649 to Brandt et al., And to the U.S. Patent. of America No. 4,467,012 granted to Pedersen and others, as well as in the published European patent application 0,339,461 granted to Kellenberger. The descriptions of these patents and of the European patent application are hereby incorporated by reference herein in their entirety.

Additionally, materials known as "slow rate" superabsorbents can also be used in the practice of the invention. By "slow rate" superabsorbent what is meant is a superabsorbent having an absorption time index (ATI) of at least 5 minutes and preferably more than 5 minutes. The adjustment of the absorbency rate of a superabsorbent can be achieved by modifications to particle size, surface properties, and polymer chemistry. Such slow rate superabsorbents are described in greater detail in U.S. Patent No. 5,843,063 issued to Anderson et al., The description of this patent is incorporated herein in its entirety.

Absorbent materials suitable for use in the practice of the invention may also take the form of absorbent foams such as open cell polyurethane foam, such as described in U.S. Patent No. 5,853,402 to Faulks et al. , whose patent description is incorporated herein in its entirety.

In addition, starch foams as described in U.S. Patent No. 5,506,277 issued to Griesbach III, whose patent description is incorporated herein in its entirety may also be used.

The invention can also use, as suitable absorbent materials, corrugated nonwoven fabrics such as the high volume corrugated nonwoven fabric described in United States of America Patent No. 3,668,054 issued to Stumpf, whose description of this patent is incorporated herein. In its whole. As described therein, such a fabric generally comprises a corrugated fabric of initially aligned textile fibers implanted in a continuous thin film of a thermoplastic adhesive having an essentially constant thickness. The resulting adhesive-woven material is then corrugated to provide the multitude of grooves and grooves, which are irregularly connected near their roots and along their respective sides.

As will be appreciated, materials suitable for use in the practice of the invention may suitably be formed in a variety of ways including being blown by melting or placed by air or formed by air. The term "meltblown fibers" generally refers to fibers formed by extruding a molten thermoplastic material through a plurality of fine matrix capillary vessels, ÍtA-áá, usually circular, as melted filaments or filaments and inside gas streams (for example air) at high speed and converging which attenuate the filaments of molten thermoplastic material to reduce their diameters. Then, the meltblown fibers are typically carried by the high velocity gas stream and are deposited on a collecting surface to form a meltblown and randomly discarded fiber fabric. The melt blown fibers may be continuous or discontinuous and are generally tacky when deposited on a collecting surface. The meltblown materials are described in greater detail in U.S. Patent No. 5,656,361 issued to Vogt et al., The disclosure of which is hereby incorporated by reference in its entirety.

In addition, the construction materials of the absorbent member which contain or include one or more of several additives such as coagulants, lysate or superabsorbents, for example, may also be used. As identified above, the adjacent absorbent materials will preferably differ in one or more properties or characteristics such as construction or chemical composition such as the orientation or thickness of the fiber, for example. According to a preferred embodiment of the invention, such adjacent absorbent members advantageously advantageously differ in a property or feature selected other than density and so that it is not readily obtainable with prior art techniques. In particular, the minimization or elimination of the horizontal dependence of the absorbent or adjacent layers or between them may result in the use of absorbent materials selected by special or particular properties or characteristics.

Furthermore, it is understood that the broadest practice of the invention is not necessarily limited to specific or particular absorbent materials and that other absorbent materials such as are known to those skilled in the art may be used if desired. For example, a wide selection of materials have been designed and developed to better manage or refer to the various conditions to which such products may be required to function.

In the practice of the invention, adjacent absorbent members may, if desired, be layered loosely or, if desired, be bonded to one another such as through the use of adhesives, thermal or ultrasonic techniques, threading or sewing techniques or other suitable joining techniques as is known in the art.

It should be understood that the broadest practice of the invention is not necessarily limited to the incorporation of absorbent pad assemblies, as described above. laáÍ, al.? .., - i .... t ** Sr í * * * *. ** í, *. ,. __ .. *, * ..... ,. "" * * T, ^ _ m ** m-,. ^ ** ^ ** k & A *** A * '* * - up, as the whole or a core essentially and completely absorbent. For example and as shown in Figures 4-10, the absorbent articles according to the invention can incorporate such absorbent pad assemblies placed in the central part of the article with other absorbent elements including possibly other absorbent, layered, folded or otherwise formed adjacent to them. In addition, and as shown in Figures 11-16, the absorbent articles according to the invention may include a central part which is formed or includes other absorbent elements with an absorbent pad assembly according to the invention in layers, folded or otherwise formed on one side thereof.

Figures 4-5 are fragmentary and simplified top views of the absorbent articles 60 and 62 respectively, in accordance with the alternate embodiments of the invention.

As shown in Figure 4, the absorbent article 60 includes a lower sheet 64, an absorbent core 66 and an upper sheet (not shown). The absorbent core 66 includes a centrally placed or placed absorbent pad assembly 70, similar to that described above, and additional absorbent elements 72 and 74 on the first and second longitudinal sides 76 and 80, respectively, thereof. As it will be appreciated and as described in more detail below, the additional absorbent elements 72 and 74 may be continuous or non-continuous or may be desired for specific applications.

Figure 5 illustrates the absorbent article 62 which includes a lower sheet 82, an absorbent core 84 and an upper sheet (not shown). The absorbent core 84 includes a centrally located absorbent pad assembly 86, similar to that described above, with an absorbent element 90 at the perimeter 92 thereof.

Figures 6-10 are sectional side views illustrating specific alternate shapes for the absorbent articles shown in Figures 4 and 5, respectively. Figure 6 illustrates an absorbent article 100 having an absorbent core 102 wherein the absorbent pad assembly 104, in accordance with the invention in general is described above and placed in an overlying manner with the absorbent element 106.

Figure 7 illustrates an absorbent article 110 having an absorbent core 112 wherein an absorbent pad assembly 144, generally in accordance with the invention as described above, is placed side by side with the absorbent elements 117 and 118, respectively . As identified above, the absorbent elements can be formed as a single member or as multiple members, as may be desired for specific applications.

Figures 8-10 illustrate the specific alternate embodiments that combine selected features of the absorbent articles 100 and 110, shown in Figures 6 and 7.

More specifically, FIG. 8 illustrates an absorbent article 120 having an absorbent core 122 wherein the absorbent pad assembly 124, in general, according to the invention as described above is positioned in both an overlying manner with an absorbent element 126. and in a side-by-side shape with the absorbent elements 127 and 128.

Figure 9 illustrates an absorbent article 130 with an absorbent core 132 that includes an absorbent pad assembly 134, as described above. The absorbent article 130 is generally similar to the absorbent article 120 shown in Figure 8, except that the underlying absorbent element 136 is formed continuous with the lateral absorbent elements 137 and 138. The side absorbent elements 137 and 138 are bent over the elbow regions 139a and 139b, respectively, to cover the absorbent element 136.

I «Í, A.- .., *? i.Jt.j Figure 10 illustrates an absorbent article 140 with an absorbent core 142 that includes an absorbent pad assembly 144, as described above. The absorbent article 140 is generally similar to the absorbent articles 120 and 130 shown in Figures 8 and 9, respectively, except for the underlying absorbent element 146 and the side absorbent elements 147 and 148 are formed continuous in mass having a generally "U-shape".

Figures 11 and 12 are fragmentary and simplified top views of the absorbent articles 160 and 162, respectively, in accordance with still further alternate embodiments of the invention.

As shown in Figure 11, the absorbent article 160 includes a lower sheet 164, an absorbent core 166 and an upper sheet (not shown). The absorbent core 166 includes an absorbent element positioned centrally opposite 170 with the absorbent pad assemblies 172 and 174, similar to those described above, on the longitudinal sides 176 and 180, respectively, thereof.

Figure 12 illustrates an absorbent article 162 which includes a lower sheet 182, an absorbent core 184 and an upper sheet (not shown). The absorbent core 184 useful a includes a centrally placed or positioned absorbent member 186 with an absorbent pad assembly 190 similar to that described above, on the perimeter 192 thereof.

Figure 13 is a cross-sectional side view of the absorbent articles as shown in Figures 11 and 12. More specifically, Figure 13 illustrates an absorbent article 200 having an absorbent core 202 that includes an absorbent element 204 having first and second parts of absorbent pad assembly 206 and 108, each in general agreement with the invention described above. In the cross-sectional view of Figure 13, the portions 206 and 208 of the absorbent pad assembly are along the longitudinal sides 210 and 212 of the absorbent element 204, respectively. It will be appreciated that the parts of the absorbent pad assembly 206 and 208 may be parts of a single absorbent pad assembly or separate absorbent pad assemblies, as described above. More specifically, even when Figure 13 has been described as being a sectional side view of the absorbent articles as shown in Figure 12, it will be understood that such an absorbent article structure may be more complicated to manufacture or produce than what can be desired. In view of the foregoing, a possibly friendlier form of process of such absorbent article will include an absorbent core element below the absorbent element 204, and such, as joined or continuous with either or both of the first and second portions 206 and 208 of the absorbent member. absorbent pad set.

It will be understood that various modifications and combinations of the modalities described above are possible and are covered here. For example, such possible modifications of the various embodiments described above may involve the inclusion of one or more underlying or underlying hollow layer or layer of another selected absorbent article material. More particularly, it may be desirable to include within an absorbent article, according to the invention, a layer of a fluid retention material that lies beneath an absorbent pad assembly, as described above. In some applications it may be desirable to include a layer of a fluid emergence material, as known in the art, in a lying-up relationship with respect to an absorbent pad assembly, as described above. In addition, the extent of such lying above or lying below, as may be the case, of each layer that lies above or lies below may be partial or complete, as may be desired for a particular application.

The absorbent structures, according to the invention, can be conveniently formed or realized by placing the selected absorbent members adjacently, as described above, and orienting the adjacently placed barrier member and the absorbent members to provide or otherwise way to result in a structure that has the desired ratio of horizontal width to vertical height. As detailed above, the structures according to the invention advantageously include the absorbent members having a horizontal width ratio at vertical height of no more than about 10: 1, preferably no more than about 5: 1, and, more preferably about 1: 1 or less. It will be understood that the formation or realization of such structures may involve the desired selection of one or more parameters or desired variables, as described above, including: the number, size and form of either or both of the members barrier and adsorbent placed adjacently as well as the properties, characteristics and materials of construction of any or both of such barrier members and absorbers, for example, and as guided by the teachings provided herein.

As will be appreciated, the absorbent members may initially be provided in various orientations so that they may or may not require a subsequent reorientation. In a particular forming method according to the invention, however, the absorbent members are horizontally layered and subsequently re-oriented vertically to provide the desired structure. ?? - .- "- ***» -. *. * **,, i ... rt. ¿.,. * _. , J,., &., »_a *. ***** &! & As described above, the absorbent and adjacent members may, if desired, be layered loosely or, if desired, may be attached to one another such as through the use of adhesives, thermal or ultrasonic, threading or sewing techniques or other suitable joining techniques as is known in the art. In accordance with a preferred practice of the invention, such joining, if desired, is preferably done before any reorientation may be required.

In addition, the methods for forming such absorbent structures according to the invention may include one or more cutting steps or operations. For example, barrier members and adjacently placed absorbers may be cut appropriately to provide or supply an absorbent pad assembly in a selected and desired shape or contour as is suitable for the specific use to which it is intended to be applied. absorbent pad set. Such a cut may occur before, after or both before and after orientation as may be desired in specific applications. Various means, as known in the art, are available whereby such cutting of adjacent barrier and absorbent members can be achieved including, for example, the cutting blade and the water jet cutting. iA - Ü, L.l i .. ** ..

Although the invention has been described in relation to absorbent articles wherein the absorbent core contains a single absorbent pad assembly according to the invention, it is understood that the broader practice of the invention is thus not necessarily limited. For example, as will be appreciated by those skilled in the art, the invention may, if desired, be practiced with absorbent articles containing two or other selected multiples of the absorbent pad assemblies. In addition, such absorbent articles may contain such two or more absorbent pad assemblies in a spaced apart, overlying, partially overlapping or other relationship, as may be desired for a particular application.

Therefore, the invention provides absorbent pad assemblies, absorbent articles and associated methods which allow a more complete or total utilization of the absorbent capacity thereof as may be desired. The invention also generally provides absorbent pad assemblies, absorbent articles and associated methods which can respond to a possibly wide range of operating and operating conditions to which such assemblies and articles can be exposed and do so in an effective and efficient.

The invention illustratively described herein may suitably be practiced in the absence of any element, part, step, component, or ingredient which is not specifically described herein.

Although the above detailed description of this invention has been made in relation to certain preferred embodiments thereof, and many details have been established for purposes of the illustration, it will be apparent to those skilled in the art that the invention is susceptible to incorporations. and that certain of the details described herein may be considerably varied if from the basic principles of the invention.

Claims

40 R E I V I N D I C A C I O N S

1 . An absorbent pad assembly comprising: at least the non-continuous vertically oriented absorbent members and first and second adjacent absorbers, one of the first and second absorbent members has a vertical height with the first and second absorbent members displaced horizontally one in relation to the other along the full vertical heights of them and forming a surface interface placed vertically between them L

2. The absorbent pad assembly such and as claimed in clause 1, characterized in that it additionally comprises: a third absorbent member vertically oriented and non-continuous positioned on one side of the second absorbent member 20 opposite the first absorbent member.

3. The absorbent pad assembly as claimed in clause 1, characterized in that the first and second absorbent members each have a different composition.

4. The absorbent pad assembly as claimed in clause 1, characterized in that the first and second absorbent members each have a width of less than about 20 millimeters.

5. The absorbent pad assembly such? as claimed in clause 4, characterized in that the first and second absorbent members each have a width of about 0.5 millimeters to about 8 millimeters.

6. The absorbent pad assembly as claimed in clause 5, characterized in that the first and second absorbent members each have a width of about 1 millimeter to about 5 millimeters.

7. The absorbent pad assembly as claimed in clause 1, characterized in that the first and second absorbent members each have a width to height ratio of less than 1.

8. The absorbent pad assembly as claimed in clause 1, characterized in that at least one of the first and second absorbent members comprises an emergence material.

9. The absorbent pad assembly as claimed in clause 1, characterized in that at least one of the first and second absorbent members comprises a superabsorbent.

10. The absorbent pad assembly such? as claimed in clause 1, characterized in that at least one of the first and second absorbent members comprises a nonwoven material made of a matrix formed of air of thermoplastic polymer fibers and a multiplicity of individualized wood pulps.

11. The absorbent pad assembly such? as claimed in clause 1, characterized in that at least one of the first and second absorbent members comprises the polymeric extruded multi-component yarns that include the first and second polymer components arranged in essentially distinctive zones through the cross-section of the multi-component threads that continuously extend along the length of the multi-component threads.

12. The absorbent pad assembly as claimed in clause 1, characterized in that at least one of the first and second absorbent members comprises an absorbent foam.

13. An absorbent article comprising: an absorbent pad set the cuajl. includes at least the generally planar, first, second and third absorbent members, each of the first, second and third absorbent members having a vertical height | L with the first and second absorbent members displaced horizontally one in relation to another throughout of the full vertical heights thereof and form a first surface interlock positioned vertically therebetween and with the second and third absorbent members displaced horizontally one in relation to the other along the full vertical heights thereof and forming a second surface grout positioned vertically therebetween, wherein at least the first and second absorbent members comprise materials of a different chemical composition.

14. The absorbent article as claimed in clause 13, characterized in that the first, second and third absorbent members each have a width of less than about 20 millimeters.

15. The absorbent pad assembly as claimed in clause 14, characterized in that the first, second and third absorbent members each have a width of about 0.5 millimeters to about 8 millimeters.

16. The absorbent article as claimed in clause 15, characterized in that the first, second and third absorbent members, each have a width of about 1 millimeter to about 5 millimeters.

17. The absorbent article as claimed in clause 13, characterized in that the first, second and third absorbent members each have a width to height ratio of less than 1.

18. The absorbent article as claimed in clause 13, characterized in that at least one of the first, second and third absorbent members comprises an emergence material.

19. The absorbent article as claimed in clause 13, characterized in that at least one of the first, second and third absorbent members comprises a superabsorbent.

20. The absorbent article as claimed in clause 13, characterized in that at least one of the first, second and third absorbent members comprises a non-woven material made of an air-shaped matrix of thermoplastic polymer fibers and a multiplicity of individualized wood pulp fibers. * *

21. The absorbent article as claimed in clause 13, characterized in that at least one of the first, second and third absorbent members comprises the polymeric extruded multi-component yarns including the first V "second polymer components arranged in essentially distinctive zones through the cross-section of the multi-component yarns extending continuously along the length of the multi-component yarns.

22. The absorbent article as claimed in clause 13, characterized in that at least one of the first, second and third absorbent members comprises an absorbent foam.

23. The absorbent article as claimed in clause 13, characterized in that it additionally comprises a lower sheet impervious to liquid on one side facing the garment of the article.

24. The absorbent article as claimed in clause 13, characterized in that it additionally comprises a liquid permeable cover on a side surface of the article. l? a -? * i ... r *: í, A

25. The absorbent article as claimed in clause 13, characterized in that it is in the form of a sanitary napkin. I

26. An absorbent article having a contact surface, the absorbent article comprises: a pad assembly which includes at least the first and second adjacent non-continuous absorbent members of different absorbency, the first and second absorbent members are generally disposed perpendicularly relative to the contact surface and form a surface interface between they also generally arranged perpendicular in relation to the contact surface.

27. The absorbent article as claimed in clause 26, characterized in that at least one of the first and second adjacent non-continuous absorbent members comprises an emergence material.

28. The absorbent article as claimed in clause 26, characterized in that at least one of the first and second adjacent non-continuous absorbent members comprises a superabsorbent.

29. The absorbent article as claimed in clause 26, characterized in that at least one of the first and second adjacent non-continuous absorbent members comprises a non-woven material made of a matrix formed by air of thermoplastic polymer fibers and a multiplicity of individualized wood pulp fibers.

30. The absorbent article as claimed in clause 26, characterized in that at least one of the first and second adjacent non-continuous absorbent members comprises the extruded multi-component polymeric strands which include the first and second polymeric components arranged in essentially distinctive zones. through the cross section of the multiple component yarns and extending continuously along the length of the multi component yarns.

31. The absorbent article as claimed in clause 26, characterized in that at least one of the first and second adjacent non-continuous absorbent members comprises an absorbent foam.

32. The absorbent article as claimed in clause 26 characterized in that they additionally comprise a lower sheet impervious to liquid on one side facing the garment of the article.

33. The absorbent article as claimed in clause 26, characterized in that they additionally comprise a liquid-permeable cover on a side surface of the article.

34. The absorbent article as claimed in clause 26, characterized in that it is in the form of a sanitary napkin.

35. A method comprising: placing adjacent at least the first and second absorbent members and orienting the first and second absorbent members positioned adjacently for each to have a ratio of horizontal width to vertical height of no more than about 10: 1.

36. The method as claimed in clause 35, characterized in that the first and second absorbent members positioned adjacently and oriented each have a ratio of horizontal width to vertical height of no more than about 1: 1.

37. The method as claimed in clause 35, characterized in that it additionally comprises: cutting the first and second absorbent members positioned adjacently to form an absorbent pad assembly.

38. The method as claimed in clause 37, characterized in that the first and second absorbent members placed adjacently are cut before orientation.

39. The method as claimed in clause 37, characterized in that the first and second absorbent members placed adjacently are cut after orientation.

40. The method as claimed in clause 37, characterized in that the cutting step comprises cutting with a cutting blade.

41. The method as claimed in clause 37, characterized in that the cutting step comprises cutting with a water jet.

42. The method as claimed in clause 35, characterized in that it additionally comprises the step of joining the first and second absorbent members placed adjacent to each other before orientation.

43. The method as claimed in clause 42, characterized in that the joining step comprises the adhesive bond.

44. The method as claimed in clause 42, characterized in that the junction comprises the thermal junction.

45. The method as claimed in Clause 42, characterized in that the joining step comprises the ultrasonic connection.

46. The method as claimed in clause 35, characterized in that the first and second absorbent members positioned adjacently and oriented each have a width of no more than about 20 millimeters.

47. The method as claimed in clause 46, characterized in that the first and second absorbent members positioned adjacently and oriented each have a width of no more than about 8 millimeters.

48. The method as claimed in clause 35, characterized in that the first and second absorbent members positioned adjacently and oriented each have a height of no more than about 15 millimeters.

49. The method as claimed in lk. clause 35, characterized in that the first and second absorbent members arranged adjacently and oriented each unp have a vertical height and are offset horizontally relative to each other along the full vertical heights thereof and form a surface interface disposed vertically between the same.

50. The method as claimed in clause 35, characterized in that the first and second absorbent members each have a different composition.

51. The method as claimed in clause 35, characterized in that the first and second absorbent members are horizontally layered and reoriented vertically in a subsequent manner.

52. The method as claimed in clause 35, characterized in that the first and second absorbent members positioned adjacently and oriented each have a width to height ratio of less than 1.

53. The method as claimed in clause 35, characterized in that at least one of the first and second absorbent members comprises an emergence material.

54. The method as claimed in clause 35, characterized in that at least one of the first and second absorbent members comprises superabsorbent if.

55. The method as claimed in clause 35, characterized in that at least one of the first and second absorbent members comprises a nonwoven material made of an air-formed matrix of thermoplastic polymer fibers and a multiplicity of pulp fibers of individualized wood.

56. The method as claimed in clause 35, characterized in that at least one of the first and second absorbent members comprises extruded multi-component polymeric yarns including the first and second polymeric components arranged in essentially distinctive zones through the section cross-section of the threads of multiple components and extending continuously along the length of the threads of multiple components.

57. The method as claimed in Clause 35, characterized in that at least one of the first and second absorbent members comprises an absorbent foam.

58. The method as claimed in clause 35, characterized in that at least one third absorbent member is positioned adjacently in relation to at least one of the first and second absorbent members and is oriented to have a width ratio horizontal at vertical height of no more than about 10: 1.

59. A method for forming an absorbent pad assembly, said method comprises: layered horizontally at least the first and second absorbent members and vertically reorient the first and second absorbent members in layers horizontally.

60. The method as claimed in clause 59, characterized in that it additionally comprises: Cut the first and second absorbent members horizontally in layers.

61. The method as claimed in clause 59, characterized in that it comprises the step of joining the first and second absorbent members horizontally in layers to one another before the vertical orientation.

62. The method as claimed in clause 59, characterized in that the first and second absorbing members vertically reoriented each have? Áp. width of no more than around 20 millimeters. I

63. The method as claimed in clause 59, characterized in that the first and second vertically reoriented absorbent members each have a width to height ratio of less than 1.

64. The method as claimed in clause 59, characterized in that at least one third absorbent member is layered horizontally relative to at least one of the first and second absorbent members is reoriented vertically.

65. In an absorbent article comprising a liquid permeable cover, a lower sheet impervious to J. liquid and an absorbent pad assembly positioned between the cover and the lower sheet, a method for improving the handling of fluid by said absorbent article, said method comprising: using an absorbent pad assembly that includes at least the first and second non-continuous vertically oriented absorbent members I and II, each of the first and second absorbent members has a vertical height with the first and second absorbent members placed horizontally one in relationship to another along the full vertical heights of the same and forming a surface interface placed vertically between them.

66. The method as claimed in clause 65, characterized in that the absorbent article is in the form of a sanitary napkin. i? rA * m ArA,. * ji, ":. iUj R E S U M E N Pad assemblies and absorbent articles are provided which include the vertically oriented non-continuous and adjacent absorbent members, displaced horizontally relative to one another along the full vertical heights thereof and forming a vertically placed surface interface. between them. A method for forming an absorbent structure is also provided in which the absorbent members are positioned adjacently and oriented such as to have a specifically desired horizontal height-to-height ratio. ll., "... _. "M .. _ a -, -, Í»