RU2799805C1 - Multilayer absorption core and manufacturing methods - Google Patents

Abstract

FIELD: absorbent elements.

SUBSTANCE: method for forming the absorbent may include moving the first cover material in the machine direction, moving the reinforcement material in the machine direction, and combining the reinforcement material with the first cover material, wherein the reinforcement material has an upper side and a lower side, applying an absorbent material containing superabsorbent material particles to the upper side of the reinforcement material, moving the second coating material in the machine direction and combining the second coating material with the first coating material and the reinforcement material to form a layered structure of the first coating material, the reinforcement material and the second coating material, where the first coating material is located under the reinforcement material and the second coating material the material is located on top of the reinforcing material, and the embossing of the layered structure.

EFFECT: invention describes multilayer absorbent elements and methods for their manufacture

17 cl, 11 dwg

Description

FIELD OF TECHNOLOGY

The present invention relates to absorbent elements, and more particularly to layered absorbent elements for use in, for example, absorbent articles.

BACKGROUND OF THE INVENTION

In their daily lives, people use disposable absorbent products, including products such as adult incontinence products, bedwetting pants, potty training pants, and diapers. Many manufacturers are striving to better meet the needs of users of such products. For example, there is a need to further improve fit, dexterity and leak protection for many products.

One important component of many absorbent articles are absorbent members, such as absorbent cores, contained in such articles. These absorbent members are generally responsible for trapping and retaining bodily fluids, thereby preventing fluids from flowing out of the absorbent article and further keeping the fluid away from the wearer's skin, thus helping to promote skin health. Advances in the structure and performance of absorbent elements to produce thinner products that absorb liquid faster and leak less are an ongoing important aspect of market demands.

BRIEF DESCRIPTION OF THE INVENTION

The present invention relates to absorbent elements, and more particularly to layered absorbent elements for use in, for example, absorbent articles.

In a first embodiment, a method for forming an absorbent member may include moving a first cover material in the machine direction, wherein the first cover material has an upper side and a lower side, moving the reinforcement material in the machine direction, and combining the reinforcement material with the first cover material, the reinforcement material having an upper side and a lower side, applying an absorbent material containing superabsorbent material particles to the upper side of the reinforcement material, moving the second cover material in the machine direction, the second cover material having an upper side and a lower side, and combining the second cover material with the first coating material and the reinforcing material to form a layered structure of the first coating material, the reinforcing material and the second coating material, where the first coating material is located under the reinforcing material, and the second coating material is located on top of the reinforcing material, and embossing the layered structure.

In a second embodiment, the absorbent may comprise a liquid-permeable top cover material, a bottom cover material, a reinforcement material positioned between the top cover material and the bottom cover material, and a superabsorbent material positioned within the reinforcement material in a sequence of high SAM concentration areas and low SAM concentration areas.

The above summary of the present invention is not intended to describe every embodiment or every embodiment of the present invention. To provide a more complete understanding of the present invention, as well as its advantages and benefits, the following is a detailed description and claims, presented in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF GRAPHICS

The present invention may be better understood by considering the following detailed description of the various embodiments in conjunction with the accompanying drawings, in which:

in fig. 1 is a perspective view of an exemplary absorbent article in a closed configuration in accordance with aspects of the present invention;

in fig. 2 is a plan view of the absorbent article of FIG. 1, in an open and horizontally stacked configuration;

in fig. 3 is a sectional view of an exemplary absorbent according to aspects of the present invention;

in fig. 4 is a schematic representation of an exemplary method for forming absorbent members according to the present invention;

in fig. 5 is a schematic representation of an exemplary method for embossing absorbent members according to the present invention;

in fig. 6A is a plan view of a portion of an exemplary embossing surface that can be used with the embossing method of FIG. 5;

in fig. 6B is a side view of a portion of an exemplary embossing surface that can be used with the embossing method of FIG. 5;

in fig. 7 is a photograph of a non-embossed reinforcing material containing particles of superabsorbent material, in accordance with aspects of the present invention;

in fig. 8 is a photograph of an embossed reinforcing material containing particles of superabsorbent material, in accordance with aspects of the present invention;

in fig. 9 is a schematic representation of an exemplary method for forming absorbent members according to the present invention; And

in fig. 10 is a sectional view of an exemplary absorbent in accordance with aspects of the present invention.

While the present invention is susceptible to various modifications and alternative forms, by way of example, features have been presented in the drawings, which will be described in detail. However, it should be understood that this is not intended to limit aspects of the present invention to the specific embodiments described. On the contrary, the present invention is intended to cover all modifications, equivalents and alternatives falling within the scope of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following description is to be read with reference to the drawings, in which similar elements are numbered the same in different drawings. The description and drawings, which are not necessarily drawn to scale, depict exemplary embodiments and are not intended to limit the scope of the present invention.

While certain suitable sizes, ranges and/or values have been disclosed regarding various components, features and/or specifications, one skilled in the art familiar with the present invention will appreciate that the desired sizes, ranges and/or values may deviate from those directly disclosed.

Each example is provided for the purpose of explanation and is not intended to be limiting. For example, features illustrated or described as part of one embodiment or figure may be used with respect to another embodiment or figure to obtain yet another embodiment. The present invention is intended to include such modifications and variations.

When presenting the elements of the present invention or its preferred embodiment(s) of implementation, the use of terms in the singular or plural, as well as accompanied by the definition of "specified" implies that there are one or more elements. The terms "comprising", "including" and "having" have an inclusive meaning and mean that there may be additional elements other than those listed. Without departing from the essence and scope of the present invention, many modifications and changes can be made to it. Therefore, the exemplary embodiments described above should not be used to limit the scope of the present invention.

In the context of this description, each term or expression below will have the following meaning or meanings. Additional terms are defined in the description in other parts.

The term "absorbent article" or "absorbent garment" in this document refers to an article that can be placed close to or adjacent to (i.e., in contact with) the wearer's body to absorb and contain various liquid, solid, and semi-solid excretions excreted from the body. Absorbent articles such as those described herein should be discarded after a limited period of use and not laundered or otherwise recovered for reuse. It is to be understood that the present invention is applicable to various disposable absorbent articles, including, but not limited to, diapers, potty training briefs, teen briefs, briefs and incontinence products, and the like, without departing from the scope of the present invention.

The term "air laid" in this document refers to a web made by air laying. In the air laying process, bundles of small fibers, typically in the range of about 3 mm to about 52 mm, are separated and entrained in the air supply and then deposited on the forming grid, usually by vacuum. The randomly deposited fibers are then bonded together using, for example, hot air to activate the binder or latex adhesive. Air laying is described, for example, in US Pat. No. 4,640,810 to Laursen et al., which is incorporated herein by reference in its entirety for all purposes.

The word “bonded” refers to the articulation, gluing, connection, fastening of two elements, etc. Two elements will be considered to be connected to each other if they are articulated, glued, connected, fastened, etc. to each other directly or indirectly, for example in the case of being connected to an intermediate element. Bonding can take place, for example, by gluing, bonding under pressure, thermal welding, ultrasonic welding, stitching, stitching and/or welding.

The term "bonded carded web" as used herein refers to webs made from staple fibers that are passed through a combing or carding unit that separates or separates and aligns the staple fibers in the machine direction to form a generally machine direction oriented fibrous nonwoven web. This material can be bonded in ways that may include spot welding, hot air bonding, ultrasonic bonding, adhesive bonding, etc.

The term "coform" in this document refers to composite materials containing a mixture or a stabilized matrix of thermoplastic fibers and a second non-thermoplastic material. For example, coform materials can be made using a process in which at least one meltblown die is located near a chute through which other materials are added to the web during its formation. Such other materials may include, but are not limited to, fibrous organic materials such as wood or non-wood pulp, such as cotton paper, cellulose chemical fiber paper, recycled paper, cellulose fluff, as well as particles of superabsorbent material; inorganic and/or organic absorbent materials, processed polymeric staple fibers and the like. Some examples of such coform materials are disclosed in US Pat.

The word "connected" refers to the articulation, gluing, binding, fastening of two elements, etc. Two elements will be considered connected to each other when they are connected directly to each other or connected to each other indirectly, for example, when each of them is directly connected to intermediate elements.

The word "disposable" refers to products intended to be discarded after limited use, and not laundered or otherwise restored for reuse.

The words "located", "located on" and variations thereof mean that one element may be integral with another element, or that one element may be a separate structure, associated with, or placed together with, or placed next to another element.

The terms "elastic", "rubberized" and "elasticity" mean that property of a material or composite material due to which it tends to restore its original size and shape after the application of the force causing the deformation ceases.

The term "elastomeric" refers to a material or composite material that can elongate by at least 50 percent of its length in a relaxed state and which, upon cessation of the applied force, will regain at least 20 percent of its elongation. In general, it is preferred that the elastomeric material or composite material be capable of elongating at least 50 percent, more preferably at least 100 percent, and even more preferably at least 300 percent of its length in a relaxed state and, upon cessation of the applied force, regain at least 50 percent of its elongation.

The term "fibrous absorbent material" or "absorbent fibers" in this document refers to natural fibers, cellulose fibers, synthetic fibers consisting of cellulose or cellulose derivatives, such as viscose fibers; inorganic fibers consisting of an inherently wettable material, such as glass fibers; synthetic fibers made from inherently wettable thermoplastic polymers, such as particular polyester or polyamide fibers, or consisting of non-wettable thermoplastic polymers, such as polyolefin fibers, which have been hydrophilized by suitable means. The fibers can be hydrophilized, for example, by treatment with a surfactant, treatment with silica gel, treatment with a material that has a suitable hydrophilic moiety and cannot be easily removed from the fiber, or by coating a nonwettable hydrophobic fiber with a hydrophilic polymer coating during or after fiber formation.

The term "layer" when used in the singular can have a double meaning of one element or multiple elements.

The term "machine direction" (MD) refers to the length of the fabric in the direction in which it is produced, as opposed to "cross-machine direction" (CD), which refers to the width of the fabric in a direction generally perpendicular to the machine direction.

The term "element" when used in the singular can have the dual meaning of one element or multiple elements.

The term "non-woven fabric" or "non-woven fabric" in this document refers to a fabric having a structure of individual fibers or threads that are interleaved, but without the possibility of identification, as in the case of a knitted fabric. Nonwoven fabrics or webs are produced using a variety of processes, such as, for example, meltblown processes, melt spunbonding processes, hot air bonding processes for carded webs (also known as BCW and TABCW), etc.

The term "spunbond web" in this document refers to a web containing essentially continuous fibers of small diameter. Fibers are formed by extruding molten thermoplastic material from a plurality of small, typically round, die holes, the diameter of the extruded fibers then being rapidly reduced in diameter, such as by pull-out and/or other well-known techniques used in melt spunbonding technology. The manufacture of spunbond webs is described and illustrated, for example, in U.S. Patent No. 4,340,563 issued to Appel et al., No. 3,692,618 issued to Dorschner et al. 3502763 to Hartman, #3502538 to Levy, #3542615 to Dobo et al., and #5382400 to Pike et al., each of which, for all purposes, is incorporated herein in its entirety by reference. Spunbond fibers are generally non-tacky when deposited on a receiving surface. The spunbond fibers can sometimes have diameters less than about 40 microns, and often from about 5 to about 20 microns.

The terms "super absorbent polymer", "super absorbent material", "SAP" or "SAM" should be used interchangeably and should refer to polymers that can absorb and retain extremely large amounts of liquid relative to their own weight. Moisture-absorbing polymers, which are classified as hydrogels, which can be cross-linked, absorb aqueous solutions due to hydrogen bonding and other polar interaction forces with water molecules. The ability of SAP to absorb water is based in part on the degree of ionicity (a measure of the concentration of ions in an aqueous solution) and the polar functional groups of SAP, which have an affinity for water. SAP is typically prepared by polymerizing acrylic acid mixed with sodium hydroxide in the presence of an initiator to form the sodium salt of polyacrylic acid (sometimes referred to as sodium polyacrylate). Other materials such as polyacrylamide copolymer, ethylene-maleic anhydride copolymer, cross-linked carboxymethylcellulose, polyvinyl alcohol copolymers, cross-linked polyethylene oxide, and starch-grafted polyacrylonitrile copolymer are also used to make the superabsorbent polymer. In absorbent garments, SAP may be present in particulate or fiber form, or as a coating or other material or fiber.

The terms "particulate", "particulate" and the like, when used in conjunction with the term "superabsorbent polymer", refer to the shape of the individual units. Units may include flakes, fibers, clumps, granules, powders, spheres, powdered materials, or the like, and combinations thereof. The particles can have any desired shape: for example, cubic, rod-shaped, polyhedral, spherical or hemispherical, rounded or semi-rounded, angular, irregular, etc.

The terms “particulate superabsorbent polymer” and “particulate superabsorbent polymer composition” refer to the form of the superabsorbent polymer and superabsorbent polymer compositions in a separate form, wherein the “particulate superabsorbent polymer” and “particulate superabsorbent polymer composition” may have a particle size of less than 1000 µm or from about 150 µm to about 850 µm.

The term "polymer" includes, but is not limited to, homopolymers, copolymers, such as block, graft, random and alternating copolymers, terpolymers, etc., and mixtures and modifications thereof. In addition, unless specifically limited, the term "polymer" should include all possible configurational isomers of the material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic symmetries.

As used herein, the term "weight percent (%)" or "wt. %" referring to particulate components of the dry superabsorbent polymer composition is to be construed as being based on the weight of the dry superabsorbent polymer composition unless otherwise specified herein.

These terms in the remaining parts of the description may be defined by additional wording.

As shown in FIG. 1-2, the garment 20 extends along the longitudinal direction 23 and the transverse direction 22 perpendicular to the longitudinal direction 23. As used in describing various embodiments of the garment 20 according to aspects of the present invention, the terms "longitudinal" and "transverse" are used in their usual sense, as indicated by the central longitudinal axis 24 and the central transverse axis 25. The central longitudinal axis 24 lies in the plane of the garment when the garment is in fully extended and horizontal in the stowed state, while the front and back panels are separated and generally parallel to a vertical plane that bisects the standing wearer into left and right halves of the body when the garment is being worn. The central transverse axis 25 lies in the plane of the garment and is generally perpendicular to the central longitudinal axis 24. The garment 20 has a front region 30 having a front waist end edge 32, a rear region 34 having a rear waist end edge 36, and a crotch region 38 located longitudinally between the front region 30 and the rear region 34. The crotch region 38 has two transversely opposite direction of the lateral edge 39 of the perineum. The garment 20 has a garment length 21 that extends from the front waist end edge 32 to the rear waist end edge 36.

The garment 20 comprises a front panel 40, which has a leg-facing edge 44, a front panel that is longitudinally inwardly spaced from the front waist end edge 32, and first and second transversely opposite side edges 46, 48 of the front panel. The garment 20 also includes a back panel 41 that has a leg-facing edge 45, a back panel that is longitudinally inwardly spaced from the rear waist end edge 36, and first and second transversely opposite side edges 47, 49 of the back panel. The term "longitudinally inward (or inside)" as used to describe embodiments of a garment herein means longitudinally toward a central transverse axis 25. Similarly, the term "laterally inward (or inside)" as used to describe embodiments of a garment herein means laterally toward a central longitudinal axis 24. Front panel 40 is longitudinally spaced from back panel 41. Front and back panels 40 typically comprise elasticated materials to conform to the nose. the presenter.

A pair of side seams 84, 84 connects the front region 30 to the back region 34 so that the garment 20 has a waist opening 27 and a pair of leg openings 28. The side seams may be permanent but tearable, for example by means of adhesive, using thermal bonding, pressure bonding, or ultrasonic bonding, or may be more easily detached as well as reattached, for example, through the use of mechanical fasteners.

The garment 20 may further comprise at least one front leg elastic 70 adjacent to the leg edge 44 of the front panel and/or at least one back leg elastic 75 adjacent to the leg edge 45 of the back panel. Such leg elastics 70 and/or 75 provide additional resilient fastening around the leg openings 28 to improve fit and leakage protection of the garment 20 . Each leg elastic element 70, 75 may comprise one ribbon, strip or thread (or the like) of elastic material, or each may contain two, three or more ribbons, strips or threads (or the like) of elastic material. In particular embodiments, the rear leg elastic 75 and/or the front leg elastic 70 extend transversely across the entire width of the garment. In other embodiments, such as those pictorially illustrated in FIG. 1 and 2, the back leg elastic 75 may include a pair of back leg elastics, such as first and second back leg elastics 76, 77 located on opposite sides of the absorbent composite 50. Similarly, the front leg elastic 70 may include a pair of front leg elastics, such as the first and second front elements. 71, 72, which are leg elastics located on opposite sides of the absorbent composite 50. In preferred embodiments, such as those illustrated in FIG. 1 and 2, each rear legband 75 may comprise a plurality of elastomeric bands and/or each front legband 70 may comprise a plurality of elastomeric bands.

In specific embodiments, the implementation of the absorbent composite material 50 is connected to the front panel 40 and back panel 41 and between them. The absorbent composite 50 may comprise a composite structure formed from a liquid-impermeable barrier layer 52 having a width 53 and a length 51, an absorbent member 54 (sometimes referred to herein as an absorbent core) containing the absorbent material, a liquid-pervious liner material 55, and/or crotch elastic members 56. As used herein, the term "absorbent material" may mean fibrous absorbent material, super absorbent material (SAM), or a combination of both fibrous absorbent material and SAM. The absorbent member 54, in some embodiments, may comprise a layered structure that includes multiple areas of liquid absorbent materials such as fibrous absorbent material and/or SAM. Absorbent member 54 has a length of 61 and a width of 63. Further description of exemplary absorbent members 54 of the present invention is provided below with respect to FIG. 3.

It should be understood that the illustrative underpants-like garment 20 is only one possible example of an absorbent garment that can be used with the disclosed absorbent members 54 of the present invention. Garments 20 such as those shown in FIG. 1 and 2 can be generally described as garments formed using a cross machine direction (CD) manufacturing process. Alternative exemplary garments that can be used with the absorbent members 54 described may include those garments that are formed through a machine directed (MD) manufacturing process. In general, the present invention is not intended to be limited to the specifically disclosed absorbent garments. Instead, the described absorbent elements 54 can be used in any suitable frame structure to hold the described absorbent elements 54 on the wearer. In other possible envisaged embodiments, the described absorbent elements 54 may not be used with any frame structure at all. Instead, the absorbent elements 54 may be designed to be capable of being placed directly in contact with the wearer's body, for example, using an adhesive applied to the element located on the body-facing surface of the absorbent elements 54.

In FIG. 3 is an exemplary sectional view of the absorbent member 54 of FIG. 2 as viewed along line 3-3. In general, the absorbent member 54 of the present invention may comprise a number of different materials, where some of the materials are bonded to each other in layers to form the member 54.

Describing the specific embodiment of absorbent member 54 shown in FIG. 3, the exemplary absorbent member 54 includes both a back cover material 101 and a top cover material 103, both of which are positioned around a reinforcing material 116. The absorbent member 54 may further comprise a wrap material 120, which is optional in some embodiments.

The bottom cover material 101 and the top cover material 103 may be formed from any suitable materials. At least the top cover material 103 may be liquid permeable and may function well in absorbing and wicking fluid. In some embodiments, the bottom cover material 101 may also be liquid permeable and function well in absorbing and wicking fluid. Although, in other embodiments, the bottom cover material 101 may be liquid-tight to help prevent liquid from leaking out of the element 54.

Cover materials 101 and/or 103 may contain natural and synthetic fibers such as, but not limited to, polyester, polypropylene, acetate, nylon, polymeric materials, cellulosic materials, and combinations thereof. In various embodiments, the fluid transfer layer 84 may be hydrophilic. In various embodiments, the cover materials 101 and/or 103 may be hydrophobic and may be treated in any manner known in the art to render them hydrophilic. A few illustrative suitable materials include fabric materials, spunbond and/or meltblown materials (e.g., spunbond-meltblown materials and spunbond-meltblown-spunbond materials), spunlace materials, HYDROKNIT® materials, which is a class of materials commercially available from Kimberly-Clark World Wide, Inc., air-laid materials, air-bonded carded webs (TABCW), and coform materials. The cover materials 101, 103 may have basis weights ranging from about 5 grams per square meter (g/m ² ) to about 55 g/m ² . In some specific embodiments of the present invention, the top cover material 103 may be a woven, SMS, or spunbond material having a basis weight of from about 7 g/m ² to about 20 g/m ² . In other embodiments, the top cover material 103 may be a coform, spunlace, or air-laid material having a basis weight of from about 35 g/m ² to about 55 g/m ² . In other specific embodiments of the present invention, the bottom cover material 101 may be a coform, spunlace, airlaid or Hydroknit® material having a basis weight of from about 30 g/m ² to about 50 g/m ² . Although these are just a few examples. Other suitable materials and/or materials having basis weights other than the above ranges may be used in other embodiments.

The reinforcing material 116 may help provide some structural integrity to the element 54 and assist in the absorption and distribution of fluid. Another advantage of the reinforcement material 116 is that it can help stabilize the absorbent material within the absorbent body 54, such as an absorbent material contained within the reinforcement material 116. In general, the reinforcement material 116 may comprise a nonwoven material composed of a plurality of individual fibers 117. For example, the reinforcement material 116 may be a spunbond material or a spunbond-meltblown-spunbond (SMS) material. In other embodiments, the nonwoven material may be a porous nonwoven material, such as TABCW, or chemically bonded nonwoven materials, or the like. In some specific embodiments, the reinforcement material 116 may consist essentially of polyolefin bicomponent fibers or polyolefin blended bicomponent and eccentric fibers, or simply polyolefin eccentric fibers. Although it should be understood that these are just some illustrative materials. In other contemplated embodiments, other suitable materials may be used. In other embodiments, the basis weight of the reinforcement material 116 may preferably be from about 30 g/m ² to about 60 g/m ² , or from about 35 g/m ² to about 55 g/m ² , or from about 40 g/m ² to about 50 g/m ² .

Wrap material 120 may be at least partially wrapped around top cover material 103, reinforcing material 116, and bottom cover material 101. As shown in FIG. 3, wrapping material 120 may be partially wrapped around materials 101, 103 and reinforcement material 116, leaving a gap between the ends of wrapping material 120 in what is sometimes referred to as a "C-lay" configuration. Although the gap between the ends of the wrapping material 120 is shown adjacent to the bottom cover material 101, in other embodiments the gap may be located adjacent to the top cover material 103. However, in other embodiments, the wrapping material 120 may be completely wrapped around the materials 101, 103 and the reinforcing material 116 so that the materials 101, 103 and the reinforcing material 116 are completely surrounded by wrapping material 120.

The wrapping material 120 may be bonded to one of the materials 101, 103 via adhesive seams 106. Such adhesive seams 106 may extend along the length of the absorbent member 54 and be adjacent to the ends of the wrapping material 120. Although in other embodiments, other adhesive configurations may be used to bond the wrapping material 120 to the materials 101, 103 and/or the reinforcing material 116. For example, instead of adhesive seams 106, the adhesive can cover most of the side of the wrapping material 120 facing the materials 101, 103 and the reinforcing material 116 so that the wrapping material 120 bonds to the materials 101, 103 and the reinforcing material 116 throughout the structure. In other embodiments, additional adhesive seams may be used such that wrapping material 120 bonds to both materials 101, 103. In general, wrapping material 120 may be bonded to materials 101, 103 and/or reinforcing material 116 in any suitable manner.

Wrap material 120 may be comprised of woven fabric, spunbond and/or meltblown (e.g., spunbond-meltblown or spunbond-meltblown-spunbond), spunlace, HYDROKNIT®, which are a class of materials available commercially from Kimberly-Clark World Wide, Inc., air-laid, air-bonded carded (TABC) W) and coform material. The wrapping material 120 may have a basis weight of from about 8 g/m ² to about 35 g/m ² . Although it should be understood that these are only illustrative materials and base weight values. In general, any suitable material with any suitable basis weight may be used.

As previously mentioned, wrapping material 120 is optional in some embodiments. In some of these optional embodiments, the top cover material 103 may be bonded directly to the bottom cover material 101, such as an adhesive seam 106, thereby surrounding the reinforcement material 116 without the use of wrap material 120. Although it should be understood that other adhesive configurations may be used to bond the materials 101, 103 to each other in these embodiments.

In at least some of these embodiments that do not include wrapping material 120, top cover material 103 may be wrapped around reinforcing material 116 for bonding with bottom cover material 101. the bottom cover material 116 for bonding with the top cover material 103. The bottom cover material 101 or the top cover material 103 may be wrapped around the reinforcing material 116 and at least a portion of the other of the bottom cover material 101 and the top cover material 103 so as to surround at least a portion of the other of the bottom cover material 101 and the top cover material 103. In such a configuration, the wrapping material 101 or 1 03 may form a C-lay or may completely surround another material 101, 103. In other embodiments, member 54 may comprise a single cover material 101 or 103. In such embodiments, a single cover material 101 or 103 may be wrapped around the reinforcement material 116 and bonded to itself, completely surrounding the reinforcement material 116.

The absorbent member 54 may also comprise an absorbent material to provide the absorbent member 54 with favorable fluid absorption and storage qualities (eg, fluid retention). For example, absorbent member 54 may have SAM distributed throughout member 54 as shown by SAM particles 115 in FIG. 3, 7, 8, and 10. In some embodiments, the absorbent element 54 may comprise absorbent material consisting essentially of only SAM, or may comprise both SAM and fibrous absorbent material (such as fluff pulp) in other embodiments. In the present invention, the phrase "substantially only" means that the material being evaluated can be greater than or exactly 90% of the total weight of the absorbent element 54 material described. For example, when the absorbent element 54 contains an absorbent material consisting essentially of only SAM, the element 54 contains an amount of SAM that is greater than or equal to 90% of the total weight of the total absorbent material of the element 54.

In order to maintain the absorbent element 54 as a cohesive structure and to help stabilize the absorbent within the element 54, the element 54 may further comprise an adhesive. In general, adhesive may be applied to different materials of member 54 to form different adhesive layers, such as adhesive layers 105, 109. Adhesive layer 105 may be applied to bottom cover material 101 and/or to reinforcing material 116 to layer bottom cover material 101 onto reinforcing material 116. Similarly, adhesive layer 109 may be applied to top cover material 103 and/or to reinforcing material. material 116 for laminating the top cover material 103 on the reinforcing material 116.

In FIG. 4 is a schematic representation of a method 200 for manufacturing absorbent members 54 according to the present invention. In a first step, a first cover material 201 having a top side and a bottom side may be unwound from a spool that contains the material forming the first cover material 201. The first cover material 201 may correspond to the top cover material 103 previously described with respect to the absorbent members 54 of the present invention. Although in other embodiments, the implementation of the first cover material 201 may correspond to the lower cover material 101 described previously. The first adhesive 209 may be applied to the upper side of the first cover material 201 by means of the adhesive applicator 210, forming a first adhesive layer on the first cover material 201. The adhesive 209 forming the first adhesive layer may correspond to the previously described adhesive layer 109. Although in other embodiments, the adhesive 209 forming the first adhesive layer may correspond to the previously described adhesive layer 205.

As shown, a reinforcing material 202 having an upper side and a lower side may also be unwound from the reel and may be further bonded to the first cover material 201, with the adhesive 209 positioned between the top side of the first cover material 201 and the underside of the reinforcing material 202. The reinforcing material 202 may correspond to the reinforcing material 116 described above. Although in FIG. 4 shows the application of glue 209 on the upper side of the first cover material 201, in alternative embodiments, it can be carried out on the lower side of the strengthening material 202. Accordingly, glue 209 can be used to form a layered structure by joining the upper side of the first cover material 201 directly to the lower side of the strengthening material 202. As described in the present, the definition of “directly” means that two materials are connected together without a connected together without intermediate materials (in addition to the binder, such as glue). Accordingly, the top side of the first cover material 201 can be considered to be bonded directly to the bottom side of the reinforcing material 116 with the adhesive 209.

Adhesive 209 can be applied at an addition rate of from about 0.5 g/m ² to about 10 g/m ² . In other preferred embodiments, adhesive 209 may be applied at an addition rate of from about 1 g/m ² to about 5 g/m ² . The adhesive 209 may be applied in accordance with any conventional adhesive application method such as compressed air application, spray application, slot application, or the like. Additionally, any suitable arrangement may be used, including swirl patterns, seam patterns, lines, or the like.

The combined first coating material 201 and reinforcement material 202 are then transported to conveyor 240. When the first coating material 201 and reinforcement material 202 are located on conveyor 240, SAM (e.g., SAM particles 115 depicted in FIG. 3) may be distributed onto reinforcement material 202. For example, SAM may be stored in hopper 215 and may be dispensed through channel 2 16 onto reinforcement material 202. In some embodiments, hopper 215 and channel 216 may be a gravity feed system whereby SAM is dispensed from channel 216 by gravity.

The SAM is dispensed from the channel 216 in a metered manner such that a certain amount of SAM is deposited on the reinforcing material 202. The SAM can be dispensed so as to achieve an addition rate of about 90 g/m ² to about 350 g/m ² . When the SAM comes into contact with the reinforcement material 202, at least some of the SAM may penetrate the reinforcement material 202. For example, the properties of the reinforcement material 202 may be such that the voids between the fibers of the reinforcement material 202 are larger than at least some of the individual particles of the distributed SAM, so that at least some of the particles of the distributed SAM may penetrate the reinforcement material 202, at least due to gravity.

In some embodiments, the conveyor 240 may be a vacuum conveyor through which air is drawn through the first cover material 201 and the reinforcement material 202 and passes into the vacuum conveyor 240. In additional or alternative embodiments, the conveyor 240 may vibrate so as to transmit vibration to the first coating material 201 and the reinforcement material 202 when the SAM is dispensed from the hopper 215. This is an addition of energy. vacuum or vibration to the first cover material 201 and the reinforcement material 202 can help increase the penetration of the distributed SAM through the reinforcement material 202. However, in the embodiments described herein, the use of vacuum and/or vibration energy was not necessary to achieve stabilization of the described amounts of SAM within the reinforcement material 202. Although in at least some embodiments, the conveyor 240 is not needed for the SAM distribution process.

Further, the second cover material 203 may be unwound from the reel and positioned to cover the partially assembled core 211 consisting of the first cover material 201, the reinforcing material 202, and the applied SAM. In some embodiments, the second cover material 203 may be guided by the guide roll 204. The second cover material 203 may correspond to the bottom cover material 101 in some embodiments or the top cover material 103 in other embodiments.

The adhesive 205 may be applied by the adhesive applicator 212 to the underside of the second cover material 203 prior to placing the second cover material 203 on the partially assembled core 211. This second adhesive 205 may form an adhesive layer that may correspond to the adhesive layer 105. Although in other embodiments, the adhesive 205 may form an adhesive layer that may correspond to the adhesive layer 109. side of the second cover material 203 directly with the core 211 partially assembled. In practice, this results in a direct bond between the bottom side of the second cover material 203 and the top side of the reinforcing material 202. However, in other embodiments, the second adhesive 205 may be applied directly to the partially assembled core 211 prior to applying the second coating material 203 to the partially assembled core 211. For example, the second adhesive 205 may be applied directly to the top side of the reinforcement material 202 and applied SAM deposited on the reinforcement material 202.

Adhesive 205 can be applied at an addition rate of from about 0.5 g/m ² to about 10 g/m ² . In other preferred embodiments, adhesive 205 may be applied at an addition rate of from about 1 g/m ² to about 5 g/m ² . The adhesive 205 may be applied according to any conventional adhesive application method such as compressed air application, spray application, slot application, or the like. Additionally, any suitable arrangement may be used, including swirl patterns, seam patterns, lines, or the like.

The core assembly 213, consisting of the first cover material 201, the reinforcing material 202, SAM, and the second cover material 203 (as well as adhesives 209 and 205), can then be further processed. For example, the core assembly 213 may be moved to further processing units by conveyor 244. In some embodiments, the core assembly 213 may be passed through a roll nip, thereby applying pressure and/or heat to the core assembly 213. In addition or alternatively, the core assembly 213 may pass through a bonding machine to seal the side edges of the core assembly 213. In other embodiments, the core assembly may be passed into a wrapping machine where a wrapping material, such as wrapping material 120, is at least partially wrapped around the core assembly 213. At least some of these embodiments may result in adhesive lines 106 as depicted in FIG. 3.

The core assembly 213 may be further incorporated into an absorbent garment or an absorbent article precursor product. For example, process 200 may be a sub-process of an absorbent garment formation process that produces an absorbent garment product, such as article 20 of FIG. 1 and 2. In such cases, the core assembly 213 may be cut into individual absorbent members 54 for incorporation into the absorbent garment or garment precursor product. Many such processes are well known in the art. In further embodiments, after the core assembly 213 is formed, the core assembly 213 can be rolled up. Such core rolls 213 as an assembly may then be transported to a separate process for the production of absorbent garments.

In at least some embodiments, the core assembly 213 may be inverted before being applied to an absorbent garment or absorbent garment precursor product. For example, in at least some embodiments of process 200, as described with respect to FIG. 4, the absorbent element 54 is made by constructing the absorbent element 54 in an "upside down" manner. That is, in some embodiments, the first cover material 201, which is located underneath in the process 200, becomes the top cover material 103 of the absorbent element 54 when the element 54 is inverted. Such an "inverted" structure is accordingly shown in FIG. 3, where the underside of the top cover material 103 is bonded directly to the top side of the reinforcement material 116 by an adhesive layer 109, and where the underside of the reinforcement material 116 is bonded directly to the top side of the bottom cover material 101.

In constructing the absorbent member 54 in this manner, SAM is applied to the side that will become the underside (eg, garment facing side) of the reinforcement material 202 when the member 54 is placed in the product. In these embodiments, most of the SAM applied to the reinforcement material 202 remains at or near the interface between the second coating material 203 and the reinforcement material 202, while some of the SAM penetrates the reinforcement material 202.

When placed in an absorbent article such that the first cover material 201 becomes the top cover material 103 (e.g., the portion of the absorbent member 54 closest to the body-facing surface of such an article), the absorbent member 54 exhibits improved performance over other absorbent members. Since the SAM was applied to the side that becomes the underside of the reinforcement material 116, and since most of the SAM does not penetrate the reinforcement material 116 in such a way as to travel to the top cover material 103, a relatively small amount of SAM is in the vicinity of the top cover material 103. This structure provides improved performance of the absorbent member 54 as it is related to absorption rate and dryness, as will be described in more detail below.

By using the above process, it has been found that it is possible to achieve stabilization control for the required amounts of SAM in different areas of the absorbent member 54. In particular, it has been found that providing stabilization of more than about 30% and less than about 85% of the total number of 115 SAM particles in the member 54 within the reinforcing material 116 (according to the SAM stabilization area test method) results in improved performance of the absorbent member 54. In other preferred embodiments, the number of SAM particles 115, stabilized within the reinforcing material 116 may comprise from about 40% to about 75% of the total SAM particles 115 within the element 54.

In the context of this document, the term "stabilized" has the meaning of "retained". For example, when the SAM particles 115 come into contact with the adhesive layer 105, the SAM particles 115 can adhere to the adhesive layer 105 and be retained. Due to the porosity of the reinforcement material 116, at least some of the SAM particles 115 are able to penetrate the interior of the reinforcement material 116. These SAM particles 115 can pass through the pores in the reinforcement material 116 and eventually get stuck somewhere inside the reinforcement material 116, for example due to the size and/or shape and/or orientation of the fibers 117 and pores within the reinforcement material 116 and the size and shape of the particles. 115 SAM. Accordingly, these "stuck" SAM particles 115 are retained within the reinforcement material 116 and are considered to be stabilized within the reinforcement material 116. The amount of SAM stabilized in different parts of the absorbent member 54 can be determined using the SAM stabilization area test method described herein.

If the number of SAM particles 115 stabilized within the reinforcement material 116 is greater than about 85% of the total SAM particles 115 within the element 54, it has been found that gel blocking may occur within the reinforcement material 116. Gel blocking occurs due to swelling of the SAM particles 115 (due to fluid absorption), which blocks access to other SAM particles 115 by the fluid inside the reinforcement material 116 and flowing through it. Swelling can increase the flow path of the fluid within the reinforcement material 116, thereby negatively impacting (eg, increasing) liquid absorption rates, rewetting characteristics, and even the holding capacity of the element 54 compared to other elements 54 with fewer SAM particles 115 stabilized within the reinforcement material 116. 40% of the total 115 SAM particles are stabilized within the reinforcement material 116, having characteristics that are approximately 12% better than those of the absorbent corresponding to the absorbent body 54, where 85% of the total 115 SAM particles are stabilized within the reinforcement material 116.

Accordingly, it is hypothesized that when there are large proportions of SAM particles 115 stabilized within the reinforcement material 116, such as greater than about 85%, for example, such particles 115 swell and block fluid penetration paths into the reinforcement material 116, thereby increasing the wicking rate to undesirable levels. In other embodiments, it may be preferable to have no more than about 70% of the total SAM particles 115 within the element 54 stabilized within the reinforcing material 116 in order to obtain the required liquid absorption rates.

On the other hand, it has been found that if the number of SAM particles 115 stabilized within the reinforcement material 116 is less than about 30% of the total number of SAM particles 115 within the member 54, this can adversely affect the layer strength between the reinforcement material 116 and the backsheet material 101. For example, with such a low percentage of SAM particles 115 stabilized within the reinforcement material 116, a correspondingly high amount 115 SAM particles are stabilized in the adhesive layer 105. The high number of 115 SAM particles associated with the adhesive layer 105 does not leave as much open adhesive in the adhesive layer 105 to bond to the reinforcing material 116 as in other embodiments where fewer 115 SAM particles are stabilized in the adhesive layer 105. Reduced bond strength between the reinforcement material 1 16 and the bottom cover material 101 may result in deterioration of the integrity of the gasket, which may affect the performance of the element 54 as well as the comfort of the user.

With this low percentage of SAM particles 115 stabilized within the reinforcing material 116, it has also been found that "islands" of SAM can form on the adhesive layer 105. Such SAM "islands" may be the result of having too many SAM particles 115 to bind to the adhesive layer 105. As a result, the SAM particles 115 may move at the interface between the reinforcement material 116 and the backsheet material 101, eventually forming clusters or "islands". These "islands" of SAM can interfere with the ability of the element 54 to absorb and hold liquid, as well as form uncomfortable clumps within the element 54.

Accordingly, because of the aforementioned problems, it is preferred that more than about 30% and less than about 85% of the total amount of 115 SAM particles within the element 54 be stabilized within the reinforcing material 116. This range is particularly applicable when the amount of 115 SAM particles within the absorbent body is from about 90 g/m ² to about 350 g/m ² . In other preferred embodiments, there may be more than about 40% and less than about 75% of the total number of SAM particles 115 within the element 54 stabilized within the reinforcing material 116 (as determined by the SAM stabilization area test method), where the total number of SAM particles 115 within the absorbent body is from about 90 g/m ² to about 350 g/m ² .

In some specific embodiments, at least some of the SAM particles 115 may pass through all of the reinforcing material 202 during process 200. These SAM particles 115 then become stabilized by the adhesive 209 corresponding to the adhesive layer 109, as depicted in FIG. 3. However, the 115 SAM particles thus stabilized typically comprise only a small fraction of the 115 SAM particles contained in the absorbent body 54 resulting from the process 200. In general, it is desirable that the number of 115 SAM particles stabilized by the adhesive layer 109 be relatively low in order to achieve the desired absorption rates of liquid by the absorbent body 54. Swelling of the 115 SAM particles stabilized by the adhesive layer 1 09 will generally increase the fluid flow path into and through the element 54 and thereby generally result in an increase in the liquid absorption time of the element 54 compared to absorbent elements 54 having lower percentages of SAM particles 115 stabilized at the adhesive layer 109.

It has been found that the applicable range for the amount of 115 SAM particles stabilized by the adhesive layer 109 that will still provide an acceptable liquid absorption rate (time) is less than about 10% by weight of the total number of 115 SAM particles in the absorbent member 54, as determined by the SAM Stabilization Area Test Method. In other embodiments, it may be preferred that less than about 7.5%, or less than about 5%, or less than about 2.5%, or less than about 1%, or less than about 0.5% of the total SAM particles 115 of the absorbent member 54 are stabilized at the adhesive layer 109, as determined by the SAM Stabilization Area Test Method.

It has also been found that these specific stabilization percentages are applicable when the reinforcing material 116 has specific properties. For example, the absorbent body 54 may perform well in terms of absorbency and dryness when the reinforcement material 116 has a basis weight of from about 25 g/m ² to about 80 g/m ² and when the SAM particles 115 are located within the absorbent body 54 in an amount of from about 90 g/m ² to about 350 g/m ² . In other preferred embodiments, the reinforcement material 116 may have a basis weight of from about 35 g/m ² to about 70 g/m ² , or from about 40 g/m ² to about 65 g/m ² , and wherein the SAM particles 115 are located within the absorbent body 54 in an amount of from about 90 g/m ² to about 350 g/m ² .

Additionally, it may be advantageous for the reinforcement material 116 to have a thickness of from about 0.8 mm to about 3.0 mm according to the height test method after cutting the reinforcement material, detailed below. In other preferred embodiments, the reinforcement material 116 may have a thickness, according to the height test method after cutting the reinforcement material, from about 1.0 mm to about 2.5 mm. This combination of base weight and thickness provides sufficient porosity in the reinforcement material 116 to provide the desired SAM stabilization percentages detailed herein. For example, these ranges create a porosity in the reinforcement material 116 that allows the 115 SAM particles to penetrate the reinforcement material 116 and also provides sufficient volume of the reinforcement material 116 for the 115 SAM particles to penetrate to provide the required stabilization percentages.

If the reinforcement material 116 has a height that is greater than about 3.0 mm (according to the method of testing the height after cutting the reinforcement material) and has a basis weight of from about 25 g/m ² to about 80 g/m ² (depending on the specific type of reinforcement material 116), the spacing between the fibers may not allow the necessary amount of SAM particles 115 to be stabilized inside the reinforcement material 116 due to the relatively large pores inside the reinforcement material. 116 caused by high height and low base weight. In other embodiments, it may not be possible to stabilize the required amount of SAM particles 115 within the reinforcement material 116 when the reinforcement material 116 has a height that is greater than about 2.5 mm (according to the height test method after cutting the reinforcement material) and at the same time has a basis weight of from about 20 g/m ² to 60 g/m ² (depending on the particular type of reinforcement material 116).

In contrast, when the reinforcing material 116 has a height that is less than about 0.8 mm or about 1.0 mm (for any suitable basis weight, such as from about 15 g/m ² to about 150 g/m ² ), the reinforcing material 116 may not have sufficient thickness to contain and stabilize the required number of 115 SAM particles within the reinforcing material 116. In such examples, fewer 115 SAM particles , stabilized within the reinforcing material 116, leaves a relatively greater number of SAM particles 115 located at the interface between the reinforcing material 116 and the bottom cover layer 101, which can lead to problems with SAM islands and/or layer strength, as described above. In determining these problems with high and low heights of the reinforcing material 116 at the basis weights described, it should be understood that these problems were found when using amounts of 115 SAM particles required to achieve a presence of from about 90 g/m ² to about 350 g/m ² , which generally represents applicable amounts of SAM particles in absorbent articles.

Returning to process 200 of FIG. 4, where it has been described that after the core assembly 213 is formed, further processing steps may be performed. One optional post-processing step not previously described is embossing the core 213 assembly. In FIG. 5 depicts an exemplary embossing process 300 that can be used to emboss a core 213 assembly. It should be understood that while the process 300 may provide useful properties to the core assembly 213 (and thus the absorbent members 54 formed from the core assembly 213), this embossing process is a completely optional step in the process of forming the absorbent members 54.

As seen in FIG. 5, the core assembly 213 can advance towards the embossing rollers 302, 304, which form a gap. In at least some embodiments, the core assembly 213 may advance toward the embossing rollers 302, 304, with the second cover material 203 oriented upwardly so as to contact the embossing roller 302 and the first cover material 201 oriented downwardly so as to contact the embossing roller 304. As the core assembly 213 advances between the embossing rollers 302, 304, the embossing rollers 302, 304 emboss the core assembly 213. Preferably, the embossing roll 302 includes embossing elements 342 that are pressed into the core assembly 213. In the orientation described above, the embossing members 342 may be pressed into the second cover material 203 as the core assembly 213 advances between the embossing rollers 302, 304. In general, it may be most advantageous to emboss the side of the core assembly 213 to which the SAM particles 115 have been applied.

It has been found that embossing the core 213 assembly by pressing one or more embossing elements 342 into the second cover material 203 can increase the amount of SAM particles 115 stabilized within the reinforcing material 116 of the core 213 assembly. Accordingly, the embossing of the core assembly 213, and in particular the embossing of the second cover material 203 of the core 213 assembly, can help achieve the desired percentage of SAM particles 115 stabilized within the reinforcing material 116. Of course, individual absorbent members 54 may be formed from the core assembly 213 before the core assembly 213 is embossed, and these individual absorbent members 54 may be subjected to embossed individually and enjoy the benefits described in this document.

In FIG. 6A and 6B are plan view and side view, respectively, of a portion of the front surface 340 of the embossing roll 302 (shown in a flat configuration). As can be seen, the face 340 of the embossing roller 302 may comprise a plurality of embossing elements 342 having embossing surfaces 344 . In at least some embodiments, the embossing roll 304 may be a smooth roll. In some embodiments, rolls 302 and/or 304 may be heated, but this is not required in all embodiments.

In general, the embossing elements 342 may be of any suitable size and shape. In at least some embodiments, the embossing elements 342 are cone-shaped with a flat embossing surface 344 (as depicted in FIG. 6B). In other embodiments, the embossing elements 342 may be cylindrical and/or have a rounded embossing surface 344. In further embodiments, the embossing elements 342 and/or the embossing surfaces 344 themselves may be oval, rectangular, star shaped, or any other suitable shape. In other embodiments, the embossing elements 342 may form embossing strips extending transversely, longitudinally, or diagonally across the face 340 of the roller 302.

The embossing elements 342 may have a longitudinal spacing 346 and a transverse spacing 348 between adjacent embossing elements 342. The embossing surfaces 344 of adjacent embossing elements 342 may have a longitudinal spacing 352 and a transverse spacing 354 (measured from the centers of the embossing surfaces 344). In some embodiments, transverse and/or longitudinal intervals 346, 348 can be zero, so that the bases of elements 342 are adjacent to each other in the longitudinal and/or transverse directions, at the same time reaching the transverse and/or longitudinal interval between surfaces 344 for embossing such elements 342 for tissue by narrowing by narrowing on the cone of elements 342 for embarrassment for fring For their height 350, as shown in FIG. 6b.

The embossing elements 342 can generally be configured to create an embossed area on the core assembly 213 (or a separate absorbent element 54) during the embossing process 300 . The core assembly 213 or individual absorbent members 54 may have a surface facing the embossing members 342 during process 300 that becomes embossed. For example, the top surface of the second cover material 203 may be the surface of the core assembly 213 facing the embossing elements 342 during the process 300, in some of the previously described embodiments. This surface of the core assembly 213 or individual absorbent members 54 facing the embossing members 342 during process 300 has an area which may be referred to as the area of the core assembly or the area of the absorbent member.

The embossed area of the core assembly 213 or individual absorbent members 54 can be considered to be the portion of the surface of the core assembly 213 or individual absorbent members 54 that has been pitted due to the embossing process 300 . The areas of these recessed portions can be added together and then divided by the area of the core assembly or absorbent to obtain an embossed area percentage. As one simplified example, if the area of the core assembly 213 or individual absorbent member 54 is 100 sq. mm and this area of the core assembly or absorbent body was embossed with ten embossing elements 342 to form depressions, each having an area of 1 sq. mm, then the percentage of embossed area of the core assembly 213 or individual absorbent member 54 will be considered to be 10% (e.g., 10 sq. mm of embossing surfaces 344 divided by 100 sq. mm of area of the core assembly 213 or individual absorbent member 54).

In one experiment, a sequence of absorbent members 54 was made in accordance with process 200. The first of these absorbent members 54 formed was left unembossed and it was determined that in this first absorbent member 54 approximately 37.2% of the SAM particles 115 were stabilized within its reinforcement material 116. embossed area value of 8%. In this second absorbent element 54, approximately 40.5% of the SAM particles 115 were determined to be stabilized within the reinforcement material 116 of this second absorbent element 54. The third of these absorbent elements 54 formed was embossed, for example by a process such as process 300, to obtain an embossed area percentage of 12%. In this third absorbent element 54, approximately 48.9% of the SAM particles 115 were determined to be stabilized within the reinforcement material 116 of this third absorbent element 54.

Accordingly, the experiment showed that the embossing of such a core 213 in the assembly described in relation to the process 300 can increase the number of particles 115 SAM, concluded within the strengthening materials 116 core 213 in the collection (and thus absorbing elements 54 formed from such embossed core 213 in the assembly) by approximately 0.98% to about 1.06% by about 1.06% One percentage of embossed area. Therefore, it may be useful to emboss the cores 213 assemblies according to the present invention to obtain an embossed area percentage of the cores 213 assemblies ranging from greater than about 0% to about 42%. This range of embossed areas can achieve sufficient penetration of the SAM particles 115 into the reinforcement materials 116 to form absorbent members 54 having the previously described percentages of SAM particles 115 stabilized within the reinforcement materials 116.

Other preferred ranges of embossed area percentages of the cores 213 assemblies of the present invention may be from about 5% to about 35%, or from about 10% to about 30%, or from about 10% to about 25%, or from about 10% to about 20%. These smaller ranges can be more widely applied to achieve the desired percentage of stabilized SAM particles 115 within the reinforcing materials 116 of cores 213 assemblies according to the present invention. For example, the use of an embossing device (eg, comprising at least embossing rollers 302, 304) configured to achieve an embossed area percentage of the cores 213 assemblies from about 10% to about 20% may be more efficient to create cores 213 assemblies having the desired percentage of SAM particles 115 (for example, from about 30% to about 85%) stabilized within the reinforcing materials. 116 cores 213 assemblies, for cores 213 assemblies with a wider range of differences (e.g. type of reinforcing material, basis weight, thickness and added amounts of SAM, etc.) than an embossing device configured to achieve an embossed area percentage of about 0-10% or about 20-42%. The present disclosure should not be construed as limiting the applicable range of embossed area percentages from about 0% to about 42%, but should instead be taken with an understanding of the advantage of using an embossing unit configured to achieve an embossed area percentage of about 10% to 20%, such as not needing to change or adjust the embossing device (to achieve a different embossed area percentage to provide the desired percentage of 115 SAM particles, one hundred bilized within the reinforcement material 116) by changing the properties of the cores 213 assemblies, such as the composition, basis weight or height of the reinforcement material 116, or the added amount of SAM particles 115 within the cores 213 assemblies.

Returning to the embossing tab heights 350, the embossing tab heights 350 typically can range from about 0.5 mm to about 4.0 mm when used in accordance with the structures (e.g., core assemblies 213 and absorbent members 54) and materials (reinforcement material 116, cover materials 101, 103, 201, 203) disclosed herein. In general, it may be preferable that the combination of the height 350 of the projections and the spacing between the rollers 302, 304 does not create too much embossing depth. The embossing depth can be considered the distance that the elements 342 penetrate into the core assembly 213 or into a separate absorbent element 54. If the combination of the height 350 of the projections and the roll spacing creates too much embossing depth, the SAM particles 115 can be pushed through the reinforcement material 116 all the way to the first cover material 201 (or top cover material 103) and stabilize near it, for example with glue 210/109). Accordingly, this may reduce the percentage of SAM particles 115 stabilized within the reinforcing material 116 below a desired level and/or increase the percentage of SAM particles 115 stabilized near the material 201/103 to an undesirable level.

It has been found that it may be preferable that the depth of the emboss be less than about 90% of the thickness of the core assembly 213 or individual absorbent 54. In other embodiments, it may be preferable that the depth of the emboss be less than about 85%, or less than about 80%, or less than about 75%, or less than about 70% of the thickness of the core assembly 213 or individual absorbent 54. On the other hand, if the depth of the emboss is is not large enough, the efficiency of increasing the percentage of SAM particles 115 stabilized inside the reinforcing material 116 may be reduced. Accordingly, it may be preferred that the depth of embossing be greater than about 25% of the thickness of the core 213 assembly or individual absorbent member 54. In other preferred embodiments, the depth of embossing may be greater than about 30%, or greater than about 35%, or greater than about 40%, or greater than about 45%, or greater than about 50% of the thickness of the core 213 assembly, or separate absorbent element 54.

As described above and with respect to FIG. 5, process 300 is shown being performed on core assembly 213. However, in other embodiments, the implementation of the process 300 may be performed on the cores 211 in a partial collection. For example, during process 200, after the distribution of SAM particles onto the reinforcement material 116 (eg, from the hopper 215 and through the channel 216), the partially assembled core 211 containing the first cover material 201, the reinforcement material 202, and the distributed SAM particles (and possibly adhesive 209) may advance through the process 300. In such embodiments, the embossing elements 342 may to emboss the reinforcement material 202 in direct contact with the reinforcement material 202. In contrast, for the process 300 shown in FIG. 5, the embossing elements 342 can directly contact the second cover material 203 and emboss both the second cover material 203 and the reinforcement material 202 at the same time - for example, because the depth of the embossing allows the embossing elements 342 to penetrate at least some of the reinforcement material 202.

Another effect that the embossing of the core assembly 213 (and/or absorbent members 54) of the present invention has, in addition to increasing the number of SAM particles 115 stabilized within the reinforcement materials 116 of the core assemblies 113 or members 54, is that the embossing localizes at least some of the SAM particles 115 within the reinforcement materials 116. This feature is best seen in FIG. 7 and 8, which are photographs of reinforcement materials 116 removed from various absorbent members 54. The reinforcement material 116 shown in the photograph of FIG. 7 has been removed from the absorbent member 54 which has not been embossed, while the reinforcement material 116 shown in the photograph of FIG. 8 has been removed from the absorbent member 54 which has been embossed.

In FIG. 7 and 8, depicting different reinforcing materials 116, both individual SAM particles 115 and individual fibers 117 are shown in each of the reinforcing materials 116 of FIG. 7 and 8. It can be seen that the SAM particles 115 of the reinforcing material 116 of FIG. 7 are more or less randomly distributed throughout the reinforcement material 116, thereby creating a relatively uniform distribution of the SAM particles 115 throughout the reinforcement material 116. Within the reinforcement material 116 of FIG. 7, there are no regions having substantially higher concentrations of 115 SAM particles than other regions of the reinforcement material 116. Alternatively, if there are differences in microscale concentrations of 115 SAM particles, such differences are randomly oriented in the reinforcement material 116 of FIG. 7.

In contrast, it can be seen that the reinforcing material 116 of FIG. 8 has regions 275 of high concentration of SAM particles and regions 276 of low concentration of SAM particles. These areas 275, 276 of high and low concentration of SAM particles are formed in accordance with a certain arrangement. That is, these areas 275, 276 of high and low concentration of SAM particles do not occur randomly. Instead, these areas 275, 276 of high and low concentration of SAM particles are oriented in a regular repeating pattern. In the specific example of FIG. 8, regions 275 are surrounded by regions 276. Although it should be understood that other arrangements may be formed. For example, regions 275 may form longitudinal or transverse alternating bands or ribbons, with regions 276 oriented on either side of a single region 275. In other embodiments, regions 275 may be offset (lengthwise and/or transversely) relative to adjacent regions 275, instead of the alignment depicted in FIG. 8. In general, such arrangements of region 275 locations may substantially correspond to the embossing pattern used to emboss core assembly 213 or absorbent member 54. Accordingly, region 275 locations may correspond to embossed areas of reinforcement material 116.

Embossing the core assembly 213 and/or the absorbent members 54 of the present invention to produce such arrayed areas of high and low concentration of SAM particles can provide an advantage over and above the previously described benefit of embossing, which is to increase the number of SAM particles 115 stabilized within the reinforcing material 116. By forming the high and low concentration SAM regions 275, 276, fluid flows more easily through the reinforcement material 11 6 than if the SAM were more evenly distributed across the reinforcement material 116. For example, in the embodiment of FIG. 7, where the SAM particles 115 are more evenly distributed throughout the reinforcement material 116, as fluid flows into and through the reinforcement material 116, the SAM particles 115 stabilized within the reinforcement material 116 begin to absorb fluid and swell. This swelling can block the flow paths of the fluid, thereby increasing the length of the paths along which the fluid can flow through the entire reinforcement material 116. However, in the embodiment of FIG. 8, as the SAM particles 115 swell, the low SAM concentration areas 276 can remain relatively open and not blocked to provide the fluid with a better opportunity to continue flowing through the entire reinforcement material 116. This can result in improved absorption characteristics of the absorbent member 54 compared to the absorption characteristics of the non-embossed members 54.

Accordingly, embossing absorbent members 54 in the manner described herein may be useful in relation to further absorbent member structures other than the absorbent members 54 described with respect to FIG. 3. In FIG. 9 shows a schematic of an exemplary manufacturing process 200' for making further absorbent members that can be embossed in accordance with process 300 to achieve at least some of the benefits described herein. Process 200' is similar to process 200 except that process 200' includes two separate SAM distribution steps. In the process 200', SAM particles (such as SAM particles 115) can be dispensed directly onto the first coating material 201 (or onto the adhesive 209 that was located on the first coating material 201), for example from the SAM feed hopper 215a and through the channel 216a. After the distribution of SAM particles to the first coating material 201, the reinforcement material 202 can be combined with the first coating material 201, as in process 200. Then, additional SAM particles can be distributed to the reinforcement material 202, for example from the SAM feed hopper 215b and through the channel 216b, in a manner similar to that described above in relation to the process 200. The remaining steps of the process 200' are similar to those described in with respect to the process 200, such as the step of combining the second cover material 203 with the partially assembled core 211 to form the assembled core 213.

The cores 213 assemblies obtained from the process 200' may have a significantly increased percentage (of the total number of 115 SAM particles in the cores 213 assemblies from the process 200') of 115 SAM particles stabilized in the first cover material 201 compared to the percentages described for the cores 213 assemblies obtained from the process 200. These cores 213 as an assembly e made by process 200' may be processed in any manner similar to that described for core assemblies 213 made by process 200, such as by separating into separate absorbent elements and placing in absorbent garments or garment precursor products, such as depicted in FIG. 1 and 2. In at least some embodiments, this post-processing may include embossing these cores 213 assemblies made by process 200' in accordance with process 300 described herein.

In FIG. 10 is an exemplary sectional view taken along line 3-3 of FIG. 2, where the absorbent element 54 of FIG. 2 is an absorbent element formed by a 200' process. The absorbent element of FIG. 10 is designated as absorbent element 54'. As can be seen, significantly more 115 SAM particles are stabilized in this element at the top cover 103 than depicted in the absorbent element 54. The absorbent element 54' may sometimes be referred to as a five-layer composite absorbent element (or core) in the art.

Such absorbent members 54' may also benefit from the embossing process 300 described with respect to FIG. 5 as well as absorbent members 54 described with respect to FIG. 3. For example, embossing the cores 213 assemblies formed by the process 200' (or directly on the individual absorbent members 54') may further disperse the 115 SAM particles from the backsheet 203 to stabilize them within the reinforcement material 116. Additionally, the embossing may assist in localizing the 115 SAM particles within the reinforcement material 116 of the absorbent member 54' to help create areas of low SAM concentration for improved flow and penetration of fluid through the reinforcement material 116 of the absorbent member 54'.

SAM stabilization area test method:

In order to determine the amount of 115 SAM particles stabilized in different parts of an absorbent member, such as absorbent member 54, the following steps can be performed.

First, a table may be generated containing the basis weight values of the various materials that make up the absorbent body. These basis weights may be determined in accordance with the absorbent member product specification used to form such an absorbent member, or may be determined in accordance with various known analytical techniques.

Table 1 lists exemplary absorbent body components according to the absorbent body 54 described herein on the left side of Table 1. The basis weights of the various components in the absorbent body are listed in the second column. By summing the basis weight values of each component of the absorbent element, you can get the total basis weight value indicated at the bottom of the second column. The ratio for each component of the absorbent can then be calculated and recorded (in the third column) by comparing the basis weight of each component with the value of the total basis weight.

Base weight (g/m ² ) Ratio Total weight (g) Bottom wrap material (for example material 101) 50 13.2% 4.62 Adhesive layer on the underside (e.g. adhesive layer 105) 5 1.3% 0.455 SAM 240 63.5% 22.2 Reinforcing material (eg material 116) 40 10.6% 3.71 Upper side adhesive (e.g. adhesive 109) 2.5 0.7% 0.245 Top wrap material (for example material 103) 40 10.6% 3.71 Total 378 100% 35

TABLE 1

A 100mm by 100mm specimen can be carefully cut from the absorbent using sharp scissors or other suitable cutting tool. The sample is then placed on an empty pallet with the bottom wrap material facing up. The weight of the sample is then determined in grams on a scientific balance with an accuracy of at least thousandths of a gram. This total sample weight is then recorded in grams to the nearest thousandth of a gram. To help clarify this test method, a sample with a total weight of 35.00 grams will be used for illustration and calculation purposes.

The total weight of each of the absorbent core components can then be calculated using the specific ratios recorded in Table 1. For example, knowing that the back wrap material makes up 13% of the total weight of the absorbent body, it can be determined that the back wrap material weighs approximately 4.62 grams for a total sample weight of 35.00 grams. Similar total weight values can be calculated for each of the components and recorded in Table 1.

The bottom wrap material should then be sprayed with Electrolube Freeze Spray (FRE400). While holding the reinforcement material and the top wrap material, the bottom wrap material is gradually and gently peeled away from the reinforcement material. The bottom wrap material is placed in an empty pallet. The remainder of the sample (eg, reinforcement material and overwrap material) is carefully lifted and placed over the tray containing the underwrap material. The combined reinforcement material and top wrap material are then gently turned over so that the reinforcement material is facing down and the combined material is shaken transversely six (6) times such that any SAM residue not stabilized in the reinforcement material falls out and falls into the pan containing the back wrap material. During shaking, the combined material should move approximately 1 inch laterally before being reversed and the shaking should last approximately two (2) seconds.

With the bottom wrap still in the pan, in addition to any residual SAM that has been shaken out of the combined reinforcement and top wrap, the weight is recorded in grams to the nearest thousandth of a gram ("Measured Weight 1").

The reinforcing material and the top wrap material are then placed in an empty tray with the top wrap material facing upwards. The top wrap should then be sprayed with Electrolube Freeze Spray (FRE400). While holding the reinforcing material, the top wrap material is gradually and carefully peeled away from the reinforcing material. With the reinforcing material still in the pan, the weight is recorded in grams to the nearest thousandth of a gram ("Measured Weight 2").

Finally, calculations can be performed to determine the percentage of absorbent element SAM particles stabilized within or on the surface of the various components of the absorbent element. To determine the percentage of SAM particles stabilized on the surface of the bottom wrap material (eg, the number of SAM particles stabilized by the adhesive layer 105), the following calculation can be performed. The determined weight of the bottom side adhesive layer (e.g. 0.245 g in the present example) and the determined weight of the top wrap material (e.g. 3.71 g in the present example) can be subtracted from the measured weight 1. Since the measured weight 1 consists of the weight of the sample bottom wrap material, the bottom adhesive layer adhered to the bottom wrap material, the SAM particles stabilized by the bottom adhesive layer, and the remainder of the SAM particles not stabilized inside the reinforcing material (which dropped out of the reinforcing material when shaken), the resulting value is the weight, expressed in grams, of the SAM particles weighed at the time of obtaining the measured weight value of 1. This resulting value can then be divided by the determined total weight of the SAM particles in the sample (for example, 22.2 g in the present example) to obtain the percentage value of SAM stabilized at the bottom wrap material in the sample.

To determine the percentage of SAM particles stabilized within the reinforcing material, the following calculation can be performed. A certain weight of the reinforcement material (e.g. 3.71 g in the present example) can be subtracted from measured weight 2. Since measured weight 2 included only reinforcement material including SAM particles stabilized within the reinforcement material, the resulting calculation provides the total weight of the SAM particles stabilized within the reinforcement material. This total weight of the SAM particles stabilized within the reinforcing material can then be divided by the determined total weight of the SAM particles in the sample (eg 22.2 g in this example) to obtain the percentage of SAM stabilized in the reinforcing material in the sample.

Finally, to determine the percentage of SAM particles stabilized at the top wrap, the determined total weight of the SAM particles stabilized at the back wrap and the determined total weight of the SAM particles stabilized within the reinforcing material can be subtracted from the determined total weight of the SAM particles in the sample (e.g., 22.2 g in the present example). This resulting calculated weight of SAM particles stabilized at the top wrap can then be divided by the determined total weight of SAM particles in the sample to obtain the percentage of SAM particles stabilized at the top wrap.

Height test method after cutting the reinforcing material:

The material to be measured may be a raw material obtained directly from the manufacturer before the product is made from it, or obtained from a product of which this material is a component. If the material must be cut to fit in the tester, the material must be cut to at least 90 mm by 102 mm (3.5 in. by 4 in.). If the material is cut prior to testing, the material must be left alone for at least twenty minutes before the test is performed. Test conditions may be in accordance with ASTM E 171-187, Standard Atmospheres for Conditioning and Testing Materials, 1994.

The test apparatus may be a STARRET® Bulk Density Tester and the test may be performed at a controlled loading pressure of approximately 0.345 kPa (0.05 psi). Output data can be registered to the nearest 0.01mm. However, substantially equivalent equipment and settings may be used as an alternative. The STARRET® Bulk Density Tester must have a minimum line pressure of 4.2 kg/ ^cm2 (60 psi) and not to exceed 4.55 kg/ ^cm2 (65 psi). The pressure from the foot pedal to the cylinder must be adjusted to 207 kPa (30 psi). A 76.2 mm (3 in.) slab must be used. The lowering speed must be adjusted to 3 seconds plus or minus 0.5 seconds. Then, the indicator must be turned on and reset by pressing the ZERO button. Finally, the foot pedal must be released, the material to be tested must be placed on the base, and the slab must be lowered using the foot pedal. After 3 seconds, the displayed value must be read and recorded. This recorded value represents the desired height of the tested material (sometimes referred to as the volume or thickness of the material).

Examples of absorbent elements:

According to aspects of the present invention, it has been found that particular embodiments of the absorbent member 54 are particularly advantageous. According to a first preferred embodiment, the absorbent member 54 may comprise a top cover material 103 formed from a woven material, an SMS material, or a spunbond material having a basis weight of from about 7 g/m ² to about 20 g/m ² . The bottom cover material 101 according to this first preferred embodiment may be formed from a coform or spunlace material having a basis weight of from about 30 g/m ² to about 40 g/m ² . The reinforcement material 116 according to this first preferred embodiment may be composed of a polyolefin bicomponent fiber having a basis weight of from about 40 g/m ² to about 50 g/m ² . The SAM can be applied so as to form a basis weight of from about 195 g/m ² to about 225 g/m ² within the element 54 according to this first preferred embodiment.

According to a second preferred embodiment, the absorbent member 54 may comprise a top cover material 103 formed from a woven material, an SMS material, or a spunbond material having a basis weight of from about 7 g/m ² to about 20 g/m ² . The bottom cover material 101 according to this second preferred embodiment may be formed from a coform material, a spunlace material, or a HYDROKNIT® material having a basis weight of from about 40 g/m ² to about 50 g/m ² . The reinforcement material 116 according to this second preferred embodiment may be a polyolefin blended bicomponent and eccentric fiber material having a basis weight of from about 40 g/m ² to about 50 g/m ² . The SAM can be applied so as to form a basis weight of from about 205 g/m ² to about 240 g/m ² within the element 54 according to this second preferred embodiment.

According to a third preferred embodiment, the absorbent member 54 may comprise a top cover material 103 formed from a woven material, an SMS material, or a spunbond material having a basis weight of from about 7 g/m ² to about 20 g/m ² . The bottom cover material 101 according to this third preferred embodiment may be formed from a coform material, a spunlace material, or an air-laid material having a basis weight of about 40 g/m ² to about 50 g/m ² . The reinforcement material 116 according to this third preferred embodiment may be a polyolefin blended bicomponent and eccentric fiber material having a basis weight of about 40 g/m ² to about 50 g/m ² . SAM can be applied so as to form a basis weight of from about 225 g/m ² to about 255 g/m ² within the element 54 according to this third preferred embodiment.

According to a fourth preferred embodiment, the absorbent member 54 may comprise a top cover material 103 formed from a coform material, a spunlace material, or an air-laid material having a basis weight of from about 35 g/m ² to about 55 g/m ² . The bottom cover material 101 according to this fourth preferred embodiment may be formed from a coform or spunlace material having a basis weight of about 35 g/m ² to about 45 g/m ² . The reinforcement material 116 according to this fourth preferred embodiment may be a polyolefin eccentric fiber material having a basis weight of from about 30 g/m ² to about 40 g/m ² . The SAM can be applied so as to form a basis weight of from about 100 g/m ² to about 130 g/m ² within the element 54 according to this fourth preferred embodiment.

All documents mentioned in the detailed description, in appropriate part, are incorporated herein by reference, and the mention of any document should not be construed as an admission that it is prior art with respect to the present invention. If any meaning or definition of a term in this written document conflicts with any meaning or definition of a term in a document incorporated by reference, then the meaning or definition in which the term is used in this written document shall prevail.

Those skilled in the art will appreciate that the present invention may be presented in a wide variety of forms that differ from the specific embodiments described and implied herein. In particular, the various features described with respect to the various embodiments and figures should not be considered applicable to those embodiments and/or figures only. Instead, each feature described can be combined with any other feature in various possible embodiments, either with or without any of the other features described in conjunction with such features. Accordingly, within the scope of the present invention as defined in the appended claims, differences in form and detail are permitted.

Embodiments

Embodiment 1: A method for forming an absorbent member may include moving a first cover material in the machine direction, wherein the first cover material has an upper side and a lower side, moving the reinforcement material in the machine direction, and combining the reinforcement material with the first cover material, the reinforcement material having an upper side and a lower side, applying an absorbent material containing superabsorbent material particles to the upper side of the reinforcement material, moving the second cover material in the machine direction, the second cover material having an upper side and a lower side, and combining the second cover material with the first coating material and the reinforcing material to form a layered structure of the first coating material, the reinforcing material and the second coating material, where the first coating material is located under the reinforcing material, and the second coating material is located on top of the reinforcing material, and the embossing of the layered structure.

Embodiment 2: The method according to Embodiment 1, wherein the embossing of the layered structure may include embossing the upper side of the layered structure.

Embodiment 3: The method according to Embodiment 1, wherein the embossing of the layered structure may include embossing the second cover material.

Embodiment 4: The method according to any one of Embodiments 1 to 3, further comprising applying adhesive to one of the top side of the first cover material and the bottom side of the reinforcing material, and applying adhesive to one of the top side of the reinforcing material and the bottom side of the second cover material.

Embodiment 5: The method of any one of Embodiments 1-4, wherein the laminated structure may comprise a laminated area, and wherein embossing the laminated structure may include forming an embossed area of greater than about 0% of the laminated area and less than about 42% of the laminated area.

Embodiment 6: The method of any one of Embodiments 1-4, wherein the laminate may comprise a laminated area, and wherein embossing the laminate may include forming an embossed area that is greater than about 5% of the laminated area and less than about 35% of the laminated area.

Embodiment 7: The method of any one of Embodiments 1-4, wherein the laminated structure may comprise a laminated area, and wherein embossing the laminated structure may include forming an embossed area that is greater than about 10% of the laminated area and less than about 30% of the laminated area.

Embodiment 8: The method of any one of Embodiments 1-7, wherein the laminate may have a thickness, and wherein embossing the laminate may include embossing the laminate to a depth of less than about 90% of the thickness of the laminate.

Embodiment 9: The method of any one of Embodiments 1-7, wherein the laminate may have a thickness, and wherein embossing the laminate may include embossing the laminate to a depth of less than about 80% of the thickness of the laminate.

Embodiment 10: The method of any one of Embodiments 1-9, wherein the laminate may have a thickness, and wherein embossing the laminate may include embossing the laminate to a depth greater than about 40% of the thickness of the laminate.

Embodiment 11: The method according to any one of embodiments 1-10 wherein embossing the layered structure may include passing the layered structure through an embossing interval defined by a first embossing roll and a second embossing roll, the first embossing roll comprising a plurality of embossing elements protruding from the surface of the first embossing roll, wherein the height of the embossing elements is from about 0.8 mm to about 4.0 mm.

Embodiment 12: The method according to any one of Embodiments 1-11 further comprising inverting the layered structure.

Embodiment 13: The method according to any one of Embodiments 1-12, further comprising attaching the absorbent to the body of the absorbent article such that the first cover material forms the body side of the absorbent.

Embodiment 14: The method according to any one of Embodiments 1 to 13, further comprising applying an absorbent material containing superabsorbent material particles to the upper side of the first cover material.

Embodiment 15: The absorbent member may comprise a liquid-permeable top cover material, a bottom cover material, a reinforcement material disposed between the top cover material and the back cover material, and a superabsorbent material disposed within the reinforcement material in a sequence of high SAM concentration regions and low SAM concentration regions.

Embodiment 16: An absorbent member according to Embodiment 15, wherein areas of high SAM concentration can be surrounded by areas of low SAM concentration.

Embodiment 17: An absorbent member according to any one of embodiments 15 and 16, wherein areas of high SAM concentration and areas of low SAM concentration can form alternating bands within the reinforcing material.

Embodiment 18: An absorbent member according to any one of embodiments 15-17 wherein from about 30% to about 85% by weight of the total superabsorbent material located between the top cover material and the back cover material can be stabilized within the reinforcing material as determined by the SAM Stabilization Area Test Method.

Embodiment 19: An absorbent member according to any one of embodiments 15-18 wherein less than about 10% by weight of the total superabsorbent material located between the top cover material and the back cover material can be stabilized with the first adhesive layer as determined by the SAM Stabilization Area Test Method.

Embodiment 20: An absorbent member according to any one of Embodiments 15-19, wherein areas of high SAM concentration may correspond to embossed areas of the reinforcing material.

Embodiment 21: A method for forming an absorbent may include moving a first cover material in the machine direction, wherein the first cover material has an upper side and a lower side, moving the reinforcement material in the machine direction, and combining the reinforcement material with the first cover material, the reinforcement material having an upper side and a lower side, applying an absorbent material containing superabsorbent material particles to the upper side of the reinforcement material, moving the second cover material in the machine direction, and combining the second cover material with the first cover material and the reinforcement material to forming a layered structure of the first coating material, the reinforcing material and the second coating material, where the first coating material is located under the reinforcing material, and the second coating material is located on top of the reinforcing material, and embossing the layered structure.

Embodiment 22: The method of Embodiment 21, wherein embossing the reinforcement material includes embossing the reinforcement material before combining the second cover material with the first cover material and the reinforcement material to form a layered structure of the first cover material, the reinforcement material, and the second cover material.

Embodiment 23: The method according to any one of Embodiments 21 and 22, wherein the embossing of the reinforcement material includes embossing the upper side of the reinforcement material.

Embodiment 24: The method according to any one of Embodiments 21-23, further comprising embossing the second cover material, wherein the second cover material and the reinforcing material are embossed simultaneously.

Embodiment 25: The method according to any one of Embodiments 21-24, further comprising applying adhesive to one of the top side of the first cover material and the bottom side of the reinforcing material, and applying adhesive to one of the top side of the reinforcing material and the bottom side of the second cover material.

Embodiment 26: The method of any of embodiments 21-25, wherein the reinforcement material may comprise an area of reinforcement material, and wherein embossing of the reinforcement material may include forming an embossed area of greater than about 0% reinforcement material and less than about 42% reinforcement material.

Embodiment 27: The method of any of embodiments 21-26, wherein the reinforcement material may comprise an area of the reinforcement material, and wherein embossing the reinforcement material may include forming an embossed area that is greater than about 5% of the area of the reinforcement material and less than about 35% of the area of the reinforcement material.

Embodiment 28: The method of any of embodiments 21-26, wherein the reinforcement material may comprise an area of the reinforcement material, and wherein embossing the reinforcement material may include forming an embossed area that is greater than about 10% of the area of the reinforcement material and less than about 30% of the area of the reinforcement material.

Embodiment 29: The method of any one of embodiments 21-28, wherein the reinforcement material may have a thickness, and wherein embossing the reinforcement material may include embossing the reinforcement material to a depth of less than about 90% of the thickness of the reinforcement material.

Embodiment 30: The method of any one of embodiments 21-28, wherein the reinforcement material may have a thickness, and wherein embossing the reinforcement material may include embossing the reinforcement material to a depth of less than about 80% of the thickness of the reinforcement material.

Embodiment 31: The method of any one of Embodiments 21-30, wherein the reinforcement material may have a thickness, and wherein embossing the reinforcement material may include embossing the reinforcement material to a depth greater than about 40% of the thickness of the reinforcement material.

Claims (27)

1. The method of forming an absorbent element, and the method includes: moving the first cover material in the machine direction, and the first cover material has an upper side and a lower side; moving the reinforcing material in the machine direction and combining the reinforcing material with the first cover material, the reinforcing material having an upper side and a lower side; applying an absorbent material containing superabsorbent material particles to the upper side of the reinforcing material; moving the second cover material in the machine direction, the second cover material having an upper side and a lower side, and combining the second cover material with the first cover material and the reinforcement material to form a layered structure of the first coating material, the reinforcement material and the second coating material, where the first coating material is located under the reinforcement material and the second coating material is located on top of the reinforcement material; And embossing the layered structure, wherein the embossing of the layered structure includes embossing the layered structure to a depth of less than 90% of the thickness of the layered structure; while from 30% to 85% by weight of the total superabsorbent material located between the top cover material and the bottom cover material is stabilized within the reinforcing material. 2. The method according to claim. 1, characterized in that the embossing of the layered structure includes embossing the upper side of the layered structure. 3. Method according to claim 1, characterized in that the embossing of the layered structure includes embossing the second cover material. 4. The method according to p. 1, characterized in that it further comprises: applying adhesive to one of the upper side of the first cover material and the lower side of the reinforcing material; And applying adhesive to one of the upper side of the reinforcing material and the lower side of the second cover material. 5. The method of claim. 1, characterized in that the layered structure contains a layered area, and the embossing of the layered structure includes the formation of an embossed area of more than 0% of the layered area and less than 42% of the layered area. 6. The method of claim. 1, characterized in that the layered structure contains a layered area, and the embossing of the layered structure includes the formation of an embossed area of more than 5% of the layered area and less than 35% of the layered area. 7. The method according to claim 1, characterized in that the layered structure contains a layered area, and the embossing of the layered structure includes the formation of an embossed area that is more than 10% of the layered area and less than 30% of the layered area. 8. The method according to claim. 1, characterized in that the embossing of the layered structure includes embossing the layered structure to a depth of less than 80% of the thickness of the layered structure. 9. The method according to claim. 1, characterized in that the embossing of the layered structure includes embossing the layered structure to a depth of more than 40% of the thickness of the layered structure. 10. The method according to claim 1, characterized in that embossing the layered structure includes passing the layered structure through an embossing interval formed by the first embossing roller and the second embossing roller, the first embossing roller containing a plurality of embossing elements protruding from the surface of the first embossing roller, while the height of the embossing elements is from 0.8 mm to 4.0 mm. 11. The method according to p. 1, characterized in that it further includes turning over the layered structure. 12. The method of claim 1 further comprising attaching the absorbent to the body of the absorbent article such that the first cover material forms the body side of the absorbent. 13. The method of claim. 1, further comprising applying an absorbent material containing particles of superabsorbent material to the upper side of the first cover material. 14. Absorbent element containing: upper liquid-permeable cover material; bottom cover material; a reinforcing material disposed between the top cover material and the bottom cover material; And a superabsorbent material located within the reinforcement material in a sequence of high SAM concentration areas and low SAM concentration areas, where the high SAM concentration areas correspond to the embossed areas of the reinforcement material and where from 30% to 85% by weight of the total amount of superabsorbent material located between the top cover material and the bottom cover material is stabilized within the reinforcement material. 15. Absorbent body according to claim 14, characterized in that areas of high concentration of SAM are surrounded by areas of low concentration of SAM. 16. Absorbent body according to claim 14, characterized in that areas of high SAM concentration and areas of low SAM concentration form alternating bands within the reinforcing material. 17. An absorbent body according to claim 14, characterized in that less than 10% by weight of the total amount of superabsorbent material located between the top cover material and the bottom cover material is stabilized by the first adhesive layer.