MXPA05010836A - Disposable articles using high column aul superabsorbents - Google Patents
Disposable articles using high column aul superabsorbentsInfo
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- MXPA05010836A MXPA05010836A MXPA/A/2005/010836A MXPA05010836A MXPA05010836A MX PA05010836 A MXPA05010836 A MX PA05010836A MX PA05010836 A MXPA05010836 A MX PA05010836A MX PA05010836 A MXPA05010836 A MX PA05010836A
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- absorbent
- layer
- superabsorbent material
- caul
- fibers
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Abstract
The present invention relates generally to an absorbent composite for an absorbent article, and more particularly to an absorbent composite comprising fibrous material and superabsorbent material having a Column Absorbency Under Load (CAUL) above 10 g/ g. Such an absorbent composite provides a superabsorbent material having superior AUL and permeability, thereby providing improved absorption and rewetting properties. An absorbent article that contains such a composite provides improved ability to absorb and retain fluids, thus preventing excessive rewetting and leakage and making the article more comfortable to wear.
Description
DISPOSABLE ITEMS USING ABSORBENT SUPERABSORBENTS UNDER TOP COLUMN LOAD
FIELD OF THE INVENTION The present invention relates generally to an absorbent composition, and more particularly to an absorbent garment containing an absorbent composition, wherein the absorbent composition contains a superabsorbent material having
an Absorbency Under Column Load (CAUL) greater than 10g / g at 0.21 kgf / cm2 (0.3 psi). That absorbent composition optimizes the AUL and permeability at the same time, thereby providing better absorption, rewet and comfort. BACKGROUND OF THE INVENTION Disposable absorbent garments such as diapers or trainers for infants, adult incontinence products and other
These products were typically constructed with an outer moisture-proof backing sheet, an inner liner sheet in contact with the moisture permeable body, and a moisture absorbing composition or a core sandwiched between the sheets of
coating and support. Much effort has been expended to find cheap materials for absorbent compositions that exhibit favorable liquid retention and absorbency. The superabsorbent materials in the form of granules, beads, fibers, pieces of films, globules, etc., have been favored for these purposes. These superabsorbent materials are generally polymeric gelling materials that are capable of absorbing and retaining even under moderate pressure large amounts of liquid, such as water and body waste, in relation to their own weight. The superabsorbent material is generally a polymeric substance insoluble in water but swellable in water capable of absorbing water in an amount which is at least 10 times the weight of the substance in its dry form. In a type of superabsorbent material, the particles or fibers can be chemically described as having a skeleton or structure of natural or synthetic polymers with hydrophilic groups or polymers containing hydrophilic groups that are chemically d to the skeleton or structure or in an intimate mixture.
' with this. Included in this class of materials are modified polymers such as polyacrylates and cross-linked polysaccharides neutralized with sodium including, for example, cellulose and starch and regenerated cellulose, which are modified to be carboxylated, phosphonoalkylated, sulfoxylated or phosphorylated, making the polymer superabsorbent
(SAP) is highly hydrophilic. These modified polymers can also be crosslinked to reduce their solubility in water. The ability of a superabsorbent material to absorb liquid typically depends on the shape, position and / or the manner in which the particles of the superabsorbent material are incorporated in the absorbent composition. When a particle of superabsorbent material and absorbent composition is wet, it swells and forms a gel. Gel formation can block the transmission of liquid into the absorbent composition, a phenomenon called "gel block". Gel blocking prevents the liquid from diffusing rapidly or by capillary action along the "blocking" particles (eg, those particles that have swollen and touched an adjacent swollen particle), causing portions of a partially hydrated core become inaccessible to multiple doses of urine. The additional absorption of liquid by the absorbent core must take place via a diffusion process. This is typically made slower than the speed at which the liquid is applied to the core. Gel blockage often leads to leakage of the absorbent article also before all the absorbent material in the core is completely saturated. Despite the incidence of blockage by gel, superabsorbent materials are commonly incorporated in absorbent cores because they absorb and retain large amounts of liquid, still under load. However, for the superabsorbent materials to work, the liquid that is absorbed in the absorbent structure must be transported to the unsaturated superabsorbent material. In other words, the superabsorbent material must be placed in a position to come into contact with the liquid. In addition, when the superabsorbent material absorbs the liquid it must allow it to swell. If the superabsorbent material is prevented from swelling, it will stop absorbing liquids. The proper absorbency of the liquid by the absorbent core at the point of initial contact with the liquid and the rapid distribution of the liquid away from this point is desirable to ensure that the absorbent core has sufficient capacity to absorb liquids deposited subsequently. The previously known absorbent cores have thus tried to rapidly absorb and distribute large quantities of liquids through the absorbent core, while immunising the gel block during the absorption of multiple doses of liquid. In general, some of the important performance attributes of an absorbent core of a diaper (or any other absorbent garment) are the functional capacity, absorption rate, stability of the core in use, SAP AUL, ratio of fibrous material to SAP, the type and weight basis of the cement or adhesive agent used to adhere the SAP to the fibrous material or paper wrapper, and the basis weight of the core. The absorption under load or AUL means the functional capacity and the speed at which absorption occurs. U.S. Patent No. 5,147,343, the disclosure of which is incorporated herein by reference in its entirety, discloses that AUL is the ability of a superabsorbent material to swell under an applied force. Especially, the AUL is expressed as the amount (millimeters) of an aqueous solution (0.9% by weight of sodium chloride) that a superabsorbent material can absorb per gram in 1 hour under a load of
21,000 dynes per square centimeter. It is believed that the AUL is a function of both the SAP basis weight (mass per unit area) and the SAP composition used in the composition. It is known to provide absorbent compositions comprised of, for example, upper and lower layers, and a central absorbent layer containing 50% to 95% by weight of SAP. U.S. Patent No. 6,068,620, the disclosure of which is incorporated herein by reference in its entirety, discloses that the upper and lower layers are preferably comprised of toilet paper, air-swelled pulp or synthetic non-woven fibrous layers. It is said that the upper and lower layers help maintain the integrity of the core, it is said that the multilayer stratified arrangement minimizes gel blocking, and the multilayer core can be bent into various configurations. It is also known to provide absorbent cores comprised of different materials in an attempt to maximize comfort and efficiency of the core, and provide areas having varying degrees of absorbency. U.S. Patent No. 5,849,002, the description of which is incorporated herein by reference in its entirety, discloses absorbent cores having three zones: (i) an area for receiving fluids;
(ii) an area to distribute and store fluids; Y
(iii) an area to prevent leaks. The patent
No. 5,853,402, the disclosure of which is incorporated herein by reference in its entirety, discloses composite absorbent cores comprising at least one absorbent material and a porous elastic material. Other composite, zoned or multicomponent cores are disclosed in, for example, U.S. Patent Nos. 5,681,300 (combined absorbent core), 5,882,464 (fold to join two absorbent structures), 5,891,120 (SAP variable concentration through the core), 5,425,725 and 5,938,650 (cavities with SAP free of multiple fibers in the core), and 5,922,165 (method for joining external layers with the absorbent core placed between the outer layers). Descriptive descriptions of each of these documents are hereby incorporated by reference in their entirety.
SUMMARY OF THE INVENTION It has not been recognized so far that AUL and permeability are at the same time important for providing absorbent compositions. The importance of these two properties has become increasingly important since the absorbent compositions contain high concentrations of SAP and manufacturers are looking for cheap ways to provide effective leak prevention. It would be desirable to provide an absorbent composition containing a superabsorbent material having a CAUL greater than 10 g / g at 0.21 kgf / cm2 (0.3 psi) to provide better performance. The superior load and permeability absorption properties of the superabsorbent material improve the absorption and retention of the liquid by the absorbent composition and prevent excessive rewetting and leakage. It would also be desirable to provide an absorbent garment containing that absorbent composition. That absorbent garment would have a better ability to absorb and retain fluids and, as a result, prevent excessive rewetting and leakage. This also improves the comfort, fit and ease of use to the wearer of the absorbent garment. Therefore, one feature of one embodiment of the invention is that it provides an absorbent composition comprising a superabsorbent material having an absorption under column load (CAUL) greater than 10 • g / g at 0.21 kgf / cm2 (0.3 psi). A further feature of the invention is that it provides an absorbent composition that provides better ability to absorb and retain fluids. A further feature of one embodiment of the invention is that it provides an absorbent garment containing an absorbent composition comprising a superabsorbent material having an absorption under column load (CAUL) greater than 10 g / g to 0.21 kgf / cm2 (0.3 psi), where the absorbent garment has better ability to absorb and retain fluids, thus preventing excessive rewet and leakage. A further feature of one embodiment of the invention is that it provides an absorbent garment containing that absorbent composition which is relatively inexpensive to manufacture and which provides the above improved properties and which is comfortable to the wearer. Another embodiment of the invention provides an absorbent garment comprising an upper sheet, a back sheet and an absorbent composition positioned between the upper sheet and the back sheet, wherein the absorbent composition contains a superabsorbent material having an absorption under column loading. (CAUL) greater than 10 g / g at 0.21 kgf / cm2 (0.3 psi). Another feature of another embodiment of the invention is that it provides a method for manufacturing an absorbent garment including providing an upper sheet, a back sheet and an absorbent composition for a garment forming station. The absorbent composition is placed at least partially between the topsheet and the backsheet at the garment-forming station. The absorbent composition comprises a superabsorbent material having an absorption under column loading (CAUL) greater than 10 g / g at 0.21 kgf / cm2 (0.3 psi). Those and other features and advantages of the preferred embodiments will become more readily apparent when the detailed description of the preferred embodiments is given in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS Figure 1A is a cross-sectional view of an absorbent composition according to an embodiment of the invention; (absorbent layer only) Figure IB is a cross-sectional view of an absorbent composition according to another embodiment of the invention; (absorbent layer and outer layers) Figure 2 is a partially cut away view of an absorbent garment containing an absorbent composition according to an embodiment of the invention; Figure 3 is a cross-sectional view of an absorbent garment of Figure 2 taken along line A-A; Figure 4 is an illustration of an apparatus useful for carrying out the method of manufacturing an absorbent garment according to the present invention; Figure 5 is an illustration of an apparatus useful for carrying out the procedure for calculating column load absorption (CAUL); and Figure 6 is a graph showing the column load absorption (CAUL) for a number of superabsorbent polymers.
DETAILED DESCRIPTION OF THE PREFERRED MODALITIES As used herein, the terms "absorbent garment", "absorbent article" or simply "article" or "article of clothing" refer to devices that absorb and contain bodily fluids and other body exudates. More specifically, those terms refer to garments that are placed against or close to the body of a wearer to absorb and contain the different exudates discharged from the body. A non-exhaustive list of examples of absorbent garments include diapers, diaper covers, disposable diapers, trainers, feminine hygiene products and adult incontinence products. It can be claimed that these garments are discarded or partially discarded after a single use ("disposable" garments). These garments may essentially comprise a single inseparable structure ("unitary" garments), or may comprise replaceable inserts or other interchangeable parts. The present invention can be used with all of the above classes of absorbent garments, without limitation, whether disposable or otherwise. Some of the embodiments described herein provide, as an exemplary structure, a diaper for an infant, however it is not intended to limit the invention claimed to it. It should be understood that the invention encompasses, without limitation, all classes and types of absorbent garments, including those described herein. Preferably, the absorbent composition is thin to improve the comfort and appearance of a garment. As used herein and in the appended claims, the singular forms "a", "an" and "the" include plural references unless the context clearly dictates otherwise. Thus, for example, a reference to "a component" includes a plurality of those components, and a reference to "an absorbent article" is a reference to one or more absorbent and equivalent articles thereof known to those skilled in the art. technique and so on. Through that description, the expressions "upper layer", "lower layer" and "above", and "below", which refer to the different components included in the embodiments of the absorbent and absorbent core composition of the invention ( including the layers surrounding the absorbent central units) are used only to describe the spatial relationship between the respective components. The top layer or the component on top of the other component does not always need to remain vertically above the core or component, and the bottom layer or "under" component of the other component does not always need to remain vertically below the core or component. Actually, the embodiments of the invention include various configurations in which the core is bent such that the upper layer finally becomes the vertically higher and vertically lower layer at the same time. Other configurations were contemplated within the context of the present invention. The term "component" may refer, but is not limited, to the designated selected regions, such as edges, corners, sides or the like; structural members, such as elastic bands, absorbent pads, stretchable layers or panels, layers of material, or the like; or a graphic. Through that description, the term "placed" and the expressions "placed on", "placed on", "placed on", "placed on", and variations thereof (for example, a description of the article that is "placed" is interposed between the words "placed" and "over") is intended to mean that one element may be integrated with another element, or that the element may be a separate structure attached to or placed with or placed near another element. In this way, the component that is "placed on" an absorbent garment element can be formed or applied directly or indirectly to the surface of the element, formed or applied between layers of a multi-layer element, formed or applied to a substrate that is placed with or near the element, formed or applied within a layer of the element or other substrate, or other variations or combinations thereof. Through this description, the terms "top sheet" and "back sheet" denote the relationship of those materials or layers with respect to the absorbent core. It should be understood that additional layers may be present between the absorbent core and the topsheet and the backsheet, and that they may be present in layers and other additional materials on the opposite side of the absorbent core of the topsheet or the backsheet. Through this description, the expression "two fibers" is generally related to any continuous fiber. Typically two fibers are used in the manufacture of crimped fibers, and are preferably comprised of synthetic thermoplastic polymers. Usually, numerous filaments are produced by melt extrusion of the molten polymer through a multi-orifice spinner during the manufacture of synthetic thermoplastic polymer crimped fibers so that reasonably high productivity can be achieved. The groups of filaments of a plurality of spinners are typically combined into a skein which is then subjected to a stretching operation to impart the desired physical properties to the filaments comprising the skein. Throughout this description, the term "absorbent compound" generally relates to any composition containing a superabsorbent material. An "absorbent composition" preferably comprises a mixture of fibrous material and superabsorbent material, and most preferably, comprises an upper layer, a lower layer, an absorbent core layer containing a porous mixture of fibrous material or superabsorbent material placed between the layer upper and lower layer. Throughout that description, the expression "outer layers" or exteriors generally relates to a top layer and a bottom layer in spatial relationship to the central absorbent layer, but may include additional layers that may be present. The upper layer and the lower layer are preferably made of toilet paper, however, other materials such as latex or thermally bonded air blown pulp can be used (for example, the laminates available from Walkisoft, Merfin or Fort James), or synthetic, charged or hydroentangled spunbond non-woven fabrics as the top or bottom layers, or they can be added as additional layers. Through that description, the term "absorbent core" is related to an absorbent composition that is used in the manufacture of absorbent garments. Through this description, the term "superabsorbent material" is generally related to a material that can suck, absorb or gel up to about 10 times its own weight of fluid and retain this low moderate pressure, where a fluid is carried towards the molecular structure and not simply contained in the pores by which it could be expelled by compression. Through this description, the expression "superabsorbent polymer"
(SAP) relates, in general, to a type of superabsorbent material comprising a polymer. Throughout this description, the term "permeability" denotes the ability of a superabsorbent material to allow a liquid to flow through a pre-swelled gel, and not block the movement of the fluid by gel. The expression "crosslinking" as such can be used to define certain superabsorbent polymers that can be "cross-linked" and is meant to mean any bond that provides stability to the material and makes the superabsorbent material swellable with water. The invention preferably provides an absorbent article containing an absorbent composition having a superabsorbent material with a (CAUL) greater than 10 g / g to 0.21 kgf / cm2 (0.3 psi). A feature of a preferred embodiment includes a central absorbent layer positioned between an upper layer and a lower layer, wherein the central absorbent layer comprises a mixture of fibrous material and superabsorbent material through its cross section. The upper and lower layers are preferably made of toilet paper or any other suitable material, so that the liquid is absorbed into the central absorbent layer containing the superabsorbent material, where the superabsorbent material has an absorption under top column loading (CAUL) at 10 g / g at 0.21 kgf / cm2 (0.3 psi). In this regard, it is preferred that the upper layer, or the layer placed closer to the upper sheet, be liquid permeable, and the lower layer, or the layer placed closer to the back sheet, be impermeable to liquids. In another embodiment of the invention, the absorbent composition contains more than one absorbent layer. The absorbent composition and / or the absorbent garment may also include one or more additional components, such as at least one layer selected from an acquisition layer, a distribution layer, an additional fibrous layer comprising the superabsorbent material, a capillary layer , a storage layer, or combinations or fragments of those layers. In another embodiment of the invention, the absorbent composition has a central absorbent layer without an upper or lower layer. In another embodiment of the invention, the absorbent garment has a front waist region, a back waist region and a crotch region positioned between the front and back waist regions. The front waist region and the rear waist region can be associated with each other to form a waist opening, and two leg openings. Those skilled in the art recognize that "front" and "rearward" in the context of the invention denote clear purposes only for the front and back of a user, and that the absorbent article could be reversed because the "front" portion described above would become the posterior portion, and vice versa. In another embodiment of the invention, elastic leg parts are provided along the leg openings to securely hold the leg openings against the user's thighs to improve containment and adjustment. A restraint system, either resealable or permanent, preferably holds the absorbent article around the wearer's waist. The restraint system helps to associate the frontal waist region with the posterior waist region. A pair of vertical leg folds or waist containment flaps may be attached to or formed from the side surface of the upper sheet body. The invention will now be described with reference to the accompanying drawings which illustrate the preferred embodiments of the invention. For clarity, the characteristics that appear in more than one Figure have the same reference number in each Figure. Figure IA is a cross section of a preferred embodiment of an absorbent composition 28. An absorbent layer 284 contains a mixture of fibrous material 285 and superabsorbent material 286 across the cross section. Figure IB is a cross section of another preferred embodiment of an absorbent composition 28. A central absorbent layer 284 is placed between the outer layers 280, 282. In the outer layer 280 is a top layer 282 and the outer layer 282 is a bottom layer. Preferably the upper layer 280 is hydrophobic and fluid permeable, and the lower layer 282 is hydrophobic and fluid impervious. It is preferred that the upper and lower layers 280, 282 are comprised of a material selected from the group consisting of toilet paper, air-blown foamed pulp and synthetic non-woven materials. More preferably, the upper layer 280 and the lower layer 282 are comprised of the same material as the toilet paper. The superabsorbent material 286 in the absorbent layer 284 is present in any concentration, preferably in a concentration of 10% to 95% by weight. The superabsorbent material 286 and the fibrous material 285 can be blended homogeneously, arranged in a stratified distribution, or mixed heterogeneously so that cavities or pockets of superabsorbent material 286 are created. When an absorbent garment 10 is used, the absorbent composition 28 it can also be called absorbent core 28. Absorbent compositions 28 as described in Figures IA and IB are commonly used in absorbent garments to absorb and retain bodily excretions that attack the garment. Figure 2 is a partially cut away description in an exemplary embodiment of the absorbent garment 10 (preferably a disposable absorbent garment) of the present invention. The embodiment shown in Figure 2 in an infant diaper, however, this disclosure is not intended to limit the invention, and those skilled in the art appreciate that the invention charges other types of absorbent articles. For simplicity, however, the invention will be described with reference to an infant diaper. The garment 10 of Figure 2 is described in a generally flattened position, with the side connected towards the body turned downwards, and with the different elastic components described in its relaxed condition with the effect of the elastic parts removed for clarity ( when relaxed, the elastic parts typically cause the surrounding material to fold or "crumple"). In the flattened position, the garment 10 may have a structure generally in the form of an hourglass, but may also have any other form suitable for the given application, in rectangular form, a trapezoidal shape, a "T" shape, and Similar. As used herein, the longitudinal axis 100 of the garment is the size of the garment corresponding to the front forward dimension of the wearer, and the lateral axis 102 of the garment is the dimension corresponding to the dimension side next to the user. In use, the invention comprises a garment similar to a breech 10 having a region surrounding the waist and a crotch region. The region surrounding the waist may comprise a first waist region 12, positioned adjacent to, for example, the back waist region of the wearer's body, and a second waist region 14, positioned adjacent to, for example, the waist region. front waist of a user's body. The first and second regions of the waist 12, 14 may correspond to the back and front portions of the wearer's body, respectively, depending on whether the garment 10 is attached to the front or to the back of the target user. The first and second waist regions are joined at or near their side edges 18, causing the longitudinally distal edges within the garment 10 to form the perimeter of a waist opening. A crotch region 16 extends between the first and second waist regions 12, 14 and the crotch edges 22 form the perimeter of a pair of leg openings, where the garment 10 is placed on a target user. The garment 10 preferably comprises a topsheet 24, a back sheet 26, which can be substantially inked with the topsheet 24. When the garment 10 is being used, the topsheet 24 is oriented towards the wearer's body, and the backsheet 26 moves away from the wearer. An absorbent composition 28 is preferably positioned between at least a portion of the topsheet 24 and the backsheet 26. An embodiment of the present invention may comprise several additional features. One or more pairs of elastic folds 30 may extend adjacent to the crotch edges 22. Garment 10 may also comprise one or more waste or debris containment systems, such as leg folds, fixed on board 40, which preferably they extend from the second waist region 14 to the first waist region 12 along the opposite sides of the longitudinal center line 100 (only one fixed leg folding system 40 is shown in Figure 1 for the purposes of clarity). One or both of the first and second waist regions 12, 14 may be equipped with bands of elastic foam for a waist 32 or other elastically extensible material, which helps contract the garment around a user's waist, providing a better fit and prevention of leaks. The absorbent garment 10 also preferably includes fastening elements to allow attachment of the first waist region 12 to the second waist region 14. The fastening elements preferably include a pair of tongues 34 that extend laterally away from the edges. opposite sides 18 of the first waist region 12 of the garment 10. The tabs 34 may contain an elastically extensible material (not shown), and may be designed to stretch around a user's waist to provide a fit, comfort , and protection against leaks. Those resilient tabs 34 may be used as a whole, or instead of foam for the waist 34, or other elastically extensible materials 32. At least one clamping mechanism 36 (referred to collectively as "fastener 36") is attached to each tab 34. for attaching the tongue to the second waist region 14, thereby providing a garment 10 with a shape similar to that of a panty, and allowing the garment 10 to be affixed or otherwise placed on the wearer. The fasteners 36 may be attached to one or more objective devices 38 located in the second waist region 14. Although not shown in the drawings, the absorbent garment 10 may also include fasteners attached along their edges near each tongue. 34 to allow the caretaker to pull the fasteners, and not over the ends of the tabs 34, around the user and over the objective devices 38 to thereby secure the fasteners 36 to one or more objective devices 38. The different parts of the garment 10 can be joined together or associated with each other to form a structure that preferably maintains its shape during the useful life of the garment 10. As used herein, the terms "connected", "attached", "associated" and similar terms encompass configurations by which a first part is directly joined to a second part by fixing the first part directly to the second part e, indirectly linking the first part to the second part through intermediate members, and fixing the relative positions of the different parties capturing the parts among other parties. Those skilled in the art will appreciate that various methods or combinations of methods can be used to securely link the respective parts of the garment 10 together. The top sheet 24 and the back sheet 26 can be constructed from a variety of materials known in the art. The invention is not intended to be limited to any specific material for those components. The upper sheet 24 and the back sheet can be formed and sized according to the requirements of each of the different types of absorbent garments, or to accommodate various user sizes. In an embodiment of the invention in which the garment 10 is a diaper or a diaper for adult incontinence, the combination of the topsheet 24 and the backsheet 26 can have an hourglass shape, as noted in Figure 1, or may have a rectangular, trapezoidal, "T" or other shape. Due to the wide variety of support and coating constructions and materials currently available, the invention is not intended to be limited to any specific materials or constructions of those components. The backsheet 26 is preferably made of any suitable, liquid-impermeable, foldable material known in the art. Typical backsheet materials include polyethylene, polypropylene, polyester, nylon and polyvinyl chloride films and combinations of those materials. For example, the backsheet can be made of a polyethylene film having a thickness in the range of 0.02-0.04 mm. The backsheet 26 can be pigmented with, for example, titanium dioxide, to provide the garment 10 with a pleasing color or to make the backsheet 26 sufficiently opaque so that the exudates that are contained with the garment 10 they are not visible from outside the garment. In addition, the backsheet 26 can be formed in such a way that it looks opaque, for example, by using various inert components in the polymeric film and then stretching the film biaxially. Other materials for the backsheet will be readily apparent to those skilled in the art. The backsheet 26 preferably has sufficient liquid impermeability to prevent any leakage of fluids. The required level of liquid impermeability may vary between different locations on the garment 10. The backsheet 26 may further comprise separate regions having different properties. In a preferred embodiment, the portions of the backsheet 26 are air permeable to improve the breathing capacity, and therefore the comfort, of the garment 10. The different regions can be formed by making the backsheet 26 a composition. of different sheet materials, chemical treatment, heat treatment, or other processes or methods known in the art. Some regions of backsheet 26 may be fluid permeable. In one embodiment of the invention, the backsheet 26 is impermeable to fluids at the crotch 16, but is permeable to fluids at portions of the first and second waist regions 12, 14. The backsheet 26 can also be made from a multiple layer of superimposed sheets of material.
The moisture permeable topsheet 24 may be comprised of any suitable liquid-permeable material known in the art that permits the passage of liquid therethrough. The nonwoven facing sheet materials are exemplary because those materials readily allow the passage of liquids towards the underlying absorbent composition 28. Examples of suitable coating sheet materials include non-woven or carded spunbond fabrics of polypropylene, polyethylene, nylon, polyester and combinations of these materials. The backsheet 26 can be covered with a fibrous, non-woven fabric, as described, for example, in U.S. Patent No. 4,646,362 issued to Heran et al., The disclosure of which is hereby incorporated by reference herein. its entirety and in a manner consistent with this description. The materials for that fibrous outer coating include a non-woven fabric spun from synthetic fibers such as polypropylene, polyethylene or polyester fibers; a non-woven fabric of cellulosic fibers, textile fibers such as rayon fibers, cotton or the like, or a combination of cellulosic fibers and textiles; a non-woven fabric spun from synthetic fibers such as polypropylene fibers; polyethylene or polyester mixed with cellulose, pulp, or textile fibers; meltblown thermoplastic fibers, such as macrofibres or microfibres of polypropylene, polyethylene, polyester or other thermoplastic materials or mixtures of those thermoplastic microfibers or microfibres with cellulosic, pulp or textile fibers. Alternatively, the backsheet 26 may comprise three panels where a central backsheet polypanel is placed closer to the absorbent composition 28 while the backsheet non-woven side breather sheets are attached to the side edges of the backsheet. Central back sheet polipanel. Alternatively, the backsheet 26 can be formed from microporous coating polymaterial for increased breathing capacity. As illustrated in greater detail in Figure 3, the topsheet 24 can be formed of three separate portions or panels. Those skilled in the art will recognize, however, that the topsheet 24 need not be made of three separate combs, and that it may be comprised of a unitary element. A first panel of the central top sheet 301 may comprise a central top sheet panel preferably formed of a liquid permeable material that is either hydrophobic or hydrophilic. The central top sheet panel 301 can be made from any number of materials, including synthetic fibers (e.g., polypropylene or polyester fibers), natural fibers (e.g., wood or cellulose), open plastic films, cross-linked foams and porous foams. to name a few. A preferred material for a central top sheet panel 301 is a non-woven single-ply material covering material which can be made of carded fibers, bonded adhesively or thermally, perforated plastic film, spun fibers, or matted fibers with water, which generally weigh from 1.07 to 2.37 g / cm2 (0.3 to 0.7 ounces / yard2) and have a stretch in the machine direction and cross direction to the appropriate and effective machine suitable for use as a coating material for baby diapers. The central top sheet panel 301 preferably extends substantially from the second waist region 14 to the first waist region 12, or a portion thereof. The first panel of the topsheet can also completely wrap the composition 28, so that the second and third panels of the topsheet 302, 303 are placed laterally away from the side edges of the composition 28. The second and third panels of the Top sheet 302, 303 (for example, the outer panels of the topsheet), in this alternative embodiment can be placed laterally outwardly of the central topsheet panel 301. The outer panels of the topsheet 302, 303 are, preferably, substantially impervious to liquids and hydrophobic, preferably at least in the crotch area. The outer edges of the outer panels of the upper sheet can substantially follow the corresponding outer perimeter of the back sheet 26. The material for the outer portions or panels of the upper sheet is preferably polypropylene and can be woven, non-woven, spun, carded or similar, depending on the application. The inner edges 304 (Figure 3) of the outer portions or panels of the topsheet 302, 303 are preferably bonded by, for example, an adhesive, to the outer edges 305 of the lower panel portion of the topsheet 301. In the connection point with the outer edges 305 of the inner portion or panel of the upper sheet 301, the inner edges 304 of the outer portions or panels of the upper sheet 302, 303 extend upwardly to form waste containment flaps. . The waste containment flaps 40 are preferably formed of the same material as the outer portions or panels of the upper sheet 302, 303, as in the embodiment shown. They are preferably an extension of the outer portions or panels of the topsheet 302, 303. The solid waste containment flaps 40 can be treated with a suitable surfactant to modify their hydrophobicity / hydrophilicity when desired, and can be treated with ingredients for the well-being of the skin to reduce skin irritation. Alternatively, the waste containment flaps 40 can be formed as separate elements and then attached to the body side liner. In this alternative embodiment, the central portion or panel of the topsheet 301 may extend along the connection point with the waste containment flaps 40, and still extend toward the periphery of the backsheet 26. The flaps for containment of debris 40 preferably includes a portion that bends over itself to form a small enclosure. At least one, and depending on the size of the enclosure, sometimes more than one elastic member 42 can be secured in the enclosure in a stretched condition. As is well known in the art, when the elastic flap 42 attempts to assume the relaxed, undrawn condition, the waste containment flaps 40 rise above the surface of the central portion or panel of the topsheet 301. The sheet upper 24 (as well as the upper sheet portions 301, 302, 303) can be made of any suitable liquid-permeable material currently known in the art or later discovered to permit the passage of a liquid therethrough. Examples of suitable top sheet materials include spunbond or non-woven fabrics of polypropylene, polyethylene, nylon, polyester and combinations of those materials, perforated, open or crosslinked films, and the like. The non-woven materials are exemplary because those materials readily allow the passage of liquids towards the underlying absorbent composition 28. The topsheet 24 preferably comprises a single-pleat non-woven material which can be made of carded fibers, either adhesively bonded or thermally, spun fibers, or fibers entangled with water, which generally weigh 1.01-2.37 g / cm2 (0.3-0.7 oz / yd2) and have a stretch in the machine direction (longitudinal) and cross machine direction (appropriate and effective) side, suitable, to be used as a top sheet material for the given application. It is intended that the present invention is not limited to any particular method for the topsheet 24, and other top sheet morning papers will be readily apparent to those skilled in the art. The topsheet 24 may further comprise several regions having different properties. In one embodiment of the present invention, the laterally distal portions of the topsheet 24, especially those used to make the second and third panels of the topsheet 302, 303, are preferably substantially impermeable to fluids and hydrophobic, while the rest of the upper sheet 24 (for example, the central panel of the upper sheet 301) is hydrophilic and permeable to fluids. Different properties may be imparted to the topsheet, such as fluid permeability and hydrophobicity, to the topsheet 24 treating the topsheet 24 with adhesives, surfactants or other chemicals, using a composition of different materials, or by other means. The top sheet 24 can also be made of a multi-layer, superposed sheet material. The topsheet 24 can also be treated in specific areas such as the crotch region, with ingredients for skin wellness, such as aloe, vitamin E and the like. As noted elsewhere herein, the topsheet 24 and the backsheet 26 may be substantially coterminal, or may have different shapes and sizes. The particular design of the top sheet 24 and the back sheet 26 can be dictated by manufacturing considerations, cost considerations and performance considerations. Preferably, the topsheet 24 is sufficiently large to completely cover the absorbent composition 28, and the backsheet 26 is sufficiently large to prevent leakage of the garment 10. The design of the topsheet 24 and the backsheet 26 is known in the art. the technique, and an expert will be able to produce an appropriate top sheet 24 and an appropriate back sheet 26 without undue experimentation. The top sheet 24 and the back sheet 26 can be associated with each other using a variety of methods known in the art. For example, they can be thermally, ultrasonically or chemically bonded together. They can also be joined using hot melt adhesive coatings or mechanical fasteners, such as strands, clamps or staples. In one embodiment, a hydrophilic adhesive is used, such as Cyclofex sold by National Starch, a joint-stock company headquartered in Bridgewater, New Jersey, to attach the top sheet 24 to the back sheet 26. The particular bonding method can be dictated by the types of materials selected for the topsheet 24 and backsheet 26. As mentioned above, the absorbent garment 10 is preferably provided with elastic portions for the leg 30 that extend through the crotch region 16 , adjacent to the crotch edge 22. The absorbent garment 10 of the invention is also preferably provided with elastic material on the waist 32 optionally in the first and second waist regions, 12, 14, respectively, to allow and assist the Stretching around the user. The elastic waist portions 32 can be similar or different structures to impart elastic characteristics similar or different to the first and second waist regions 12, 14 of the garment. In general, the elastic waist portions 32 may preferably comprise foam bands placed in the first and second waist regions 12, 14, respectively. These foam bands are, preferably, approximately 1.27 to 3.81 centimeters (* • 1 to 1 inches) wide and approximately 7.62-15.24 centimeters (3-6 inches) in length. The foam webs are preferably placed between the upper web portions 24 or panels (301, 302, 303) and the backsheet 26. Alternatively, a plurality of elastic threads may be employed as elastic waist portions instead of the foam bands. The foam bands are preferably comprised of polyurethane, but can be of any other suitable material that decreases the winding of the band on the waist, reduces leakage on the waist ends of the absorbent garment, and generally improves comfort and fit. The first and second optional foam bands 32 are preferably stretched 50-150%, preferably 100% more than their unstretched dimension before being adhesively secured between the back sheet 26 and the top sheet 24. Each edge 22 which forms the leg openings is preferably provided with an adjacent resilient restraint system for the legs 30. In the preferred embodiment, three strands of elastic threads are placed (only two strands are shown in Figure 3 for purposes of clarity) for extending adjacent to the leg openings between the outer portions or panels of the upper sheet 302, 303 and the back sheet 26. Any suitable elastomeric material exhibiting at least one elongation (defined herein as (LS-LR) / LR where Ls is a stretched length of an elastic element and LR is the retracted length, multiplied by 100 to obtain the percent of lengthening nto) in the range of 5% -350%, preferably in the range of 200% -300%, for the elastic parts of the leg 30. The elastic parts for the legs 30 can be attached to the absorbent article 10 in any of several forms known in the art. For example, the elastic parts for the legs 30 can be ultrasonically bonded, heat sealed / pressed using a variety of bonding patterns, or enrobed to the garment 10. Various commercially available materials can be used for the elastic portions of the garments. legs 30, such as natural rubber, butyl rubber or other synthetic rubber, urethane, elastomeric materials such as LYCRA (DuPont), GLOSPAN (Globe) or SYSTEM 7000 (Fulflex). The fastening elements, preferably a fastening system 34 (for example, the tongue 34) of the preferred embodiment, is attached to the first region of the waist 12 and preferably comprises a tongue of mechanical tape or fasteners 36. However, any Clamping mechanism known in the art will be acceptable. In addition, the fastening system 34 may include a reinforcing patch below the front portion of the waist so that the diaper can be checked to see if it is dirty without compromising the ability to reuse the fastener. Alternatively, other systems for securing the absorbent article, including safety pins, buttons and pressure locks, are also possible. As stated above, the invention has been described in connection with a diaper. The invention, however, is not intended to be limited to its application only to diapers. Specifically, the absorbent compositions of the preferred embodiments may be readily adapted for use in other absorbent garments in addition to diapers, including, but not limited to, trainers, female sanitary products and adult incontinence products. The underlying structure beneath the topsheet 24 may include, depending on the construction of the diaper, various combinations of elements, but in each embodiment, it was contemplated that the absorbent garment 10 preferably includes an absorbent composition 28. In addition, they may be placed additional layers between the topsheet 24 and the absorbent composition 28, or between the absorbent composition 28 and the backsheet 26. An additional layer may also be included in the absorbent composition 28. The additional layers may include a fluid transfer layer, a fluid handling layer, a storage layer, a capillary layer, a fluid distribution layer, or any other layers known to those skilled in the art. Although the absorbent composition 28 described in Figure 3 has a substantially rectangular cross-sectional shape in a flat view, other shapes can be used, such as a "T" shape or an hourglass shape. The shape of the absorbent composition 28 can be selected to provide the highest absorbency with a reduced amount of material. The absorbent composition may be associated with the topsheet 24, the backsheet 26, or any other suitable part of the garment 10 or by any method known in the art, to secure the absorbent composition 28 in place. In addition to the respective layers in the absorbent composition 28, as will be described in greater detail hereinafter, the total absorbent composition 28 can be enclosed within a toilet paper wrapper, as shown in Figure IB and described in the US Pat. No. 6,068,620, the description of which is incorporated herein by reference in its entirety. The experts will be able to design and roll up a suitable absorbent composition 28 of the invention, using the guidance provided herein. In a preferred embodiment, the central absorbent layer 284 of the absorbent composition 28 comprises superabsorbent polymer distributed within a fibrous structure. Central absorbent layers 284 of this type are generally known in the art, and exemplary absorbent cores are described in U.S. Patent No. 6,068,620 and U.S. Patent No. 5,281,207, both issued to Chmielewski, and U.S. Patent No. 5,863,288, issued to Baker, the descriptions of each of which are hereby incorporated by reference in their entirety and in a manner consistent with this description. Preferably certain fibrous additives and particles are used as constituent elements of the absorbent composition 28 to maintain high SAP efficiencies when the SAP concentration is in the range of about 10-95%, more preferably about 40-90%, and more preferably about 50-85%. The superabsorbent polymers of the surface crosslinked variety work best in these multilayers. These additives are preferably constituent elements of the central absorbent layer 284, and can be added to any additional layers. The fibrous component of the central layer 284 of the absorbent composition 28 can be any fibrous material now known or subsequently discovered. Suitable fibrous materials include fluff pulp, hard and soft Kraft woods, and the like. The fibrous component is preferably comprised of tow fiber, and more preferably is a tow or skein of cellulose acetate or polyester. Before manufacturing the absorbent composition including a tow fiber, the tow fiber is typically unwound and opened and then cut into various lengths to provide a fibrous mass of material. Those skilled in the art are aware of techniques available to open tow or skein fibers and form open fibers in a fibrous mass. In addition to the tow or skein material used as the fibrous component in the central absorbent layer 284, other fibrous components may also be used. For example, additional tow or skein fibers (different from the original tow or skein fiber), or a low density rolled product made from a separate process can be used in the central absorbent layer 284. Moreover, the fibrous component also It could be a carded cloth formed in line. Optionally, it is advantageous to introduce from about 1-5% of a thermally bondable fiber to the fibrous component of the central absorbent layer 284 for wet stretching and stability of the core in use. To maintain high SAP concentrations, the concentration of fibrous material in the central layer 284 of the absorbent composition 28 of the invention is preferably about 5-90%, more preferably about 10-60%, and more preferably about 15-50%. More preferably, the central absorbent layer 284 comprises about 75-85% of SAP and about 15-25% of fibrous materials selected from the above group, in the following fibrous components described below. The particulate additives may be added to the central absorbent layer 284 in addition to or as substitutes for the above fibrous additives to maintain a high SAP efficiency. The particulate additives are preferably insoluble, hydrophilic polymers, with particle diameters of 100 or less. The particulate additives are chosen to impart an optimum separation of the SAP particles. Examples of preferred particulate additive materials include, but are not limited to, potato, corn, wheat and rice starches. Partially cooked or chemically modified starches (ie, hydrophobicity, hydrophilicity, softness and modified hardness) can also be effective. More preferably, the particulate additives comprise corn starch or partially cooked wheat because in this state, the corn or wheat becomes larger than the uncooked starch and even in the cooked state they remain harder than the swollen SAP. In any case, regardless of the chosen particulate additive, one of the most important criteria is the use of particulate additives that are hard hydrophilic materials relative to swollen SAP or that are organic or inorganic polymeric materials of approximately 100 microns in diameter. The fibrous and particulate additives can be used together in these absorbent multilayers. Examples of SAP / particulate and SAP / fibrous / particulate additives include those described in, for example, U.S. Patent No. 6,068,620. Any superabsorbent polymer (SAP) now known or later discovered in the central absorbent layer 284 may be used as long as it is capable of absorbing liquids and as long as it has a CAUL greater than 10 g / g to 0.21 kgf / cm2 (0.3 psi). Useful SAP materials are those that are generally insoluble in water but water swellable polymeric substances capable of absorbing water in an amount that is at least 10 times the weight of the substance in its dry form. In a type of SAP, the particles or fibers can be described chemically as having a skeleton or structure of natural or synthetic polymers with hydrophilic groups or polymers containing hydrophilic groups that are chemically bound to the skeleton or structure or in intimate admixture with it. Included in this class of materials are modified polymers such as polyacrylates and reticulated polysaccharides naturalized with sodium, including, for example, cellulose and starch and regenerated cellulose, which are modified to be carboxylated, phosphonoalkylated, sulfoxylated, or phosphorylated, causing the SAP is highly hydrophilic. These modified polymers can also be crosslinked to reduce their solubility in water. Examples of suitable SAPs are water-swellable polymers of acrylic monomers or water-soluble vinyls cross-linked with a polyfunctional reagent. Also included are polyacrylic acids modified with hydrolyzed starch and polyacrylonitrile and their alkali metal salts. In accordance with the present invention, the central absorbent layer 284 may be based on a tow or skein fiber, and preferably, a continuous crimped filament tow. The structure of the fiber has a high structural integrity, and is therefore distinct from a matrix of discontinuous fibers described as a sponge or fluff pulp in the prior art. The high structural integrity allows the production of fabrics stronger than those formed from discontinuous fibers, which in turn is believed to allow the production of thinner absorbent pads containing the same or more SAP than the "thicker" conventional pads until now. The invention is not limited, however, to thin absorbent compositions, or absorbent compositions employing tow fibers. The tow fiber can be any tow fiber of continuous or discontinuous thermoplastic filaments that can be opened and used in combination with the SAP in an absorbent core. Preferably, cellulose ester tow is used as the fibrous material in the central absorbent layer 284. Non-limiting examples of suitable cellulose esters include cellulose acetate, cellulose propionate, cellulose butyrate, cellulose caproate, cellulose caprylate , cellulose stearate, highly acetylated derivatives thereof such as cellulose diacetate, cellulose triacetate and cellulose tricaproate and mixtures thereof such as cellulose acetate butyrate. A suitable cellulose ester will include the ability to absorb moisture, preferably is biodegradable, and is influenced not only by substituent groups but also by the degree of substitution. The relationship between substituent groups, the degree of substitution and biodegradability are discussed in. G. Glasser et al., BIOTECHNOLOGY PROGRESS, vol. 10, pp. 214-219 (1994), the description of which is incorporated herein by reference. The continuous filament tow useful in the present invention is, beneficially, moisture absorbent and biodegradable. Accordingly, cellulose acetate tow is typically preferred for use in the invention. Typically, the fiber denier (dpf) of the tow fiber is in the range of about 1 to 9, preferably 3 to 6. For the product of the same weight, the smaller dpf filaments can provide a larger surface area and greater moisture absorption. The total denier can vary within the range of approximately 20,000 to 60,000 depending on the process used. It is preferred, particularly in the invention, to use a tow having crimped filaments. Bast materials that have crimped filaments are typically easier to open. The separation of the resultant filaments from the loom advantageously results in an increase in the surface area of the available filament for the immobilization of the superabsorbent material and a greater absorption of moisture. The gel block can also be reduced by using crimped tow in the central absorbent layer 284. Therefore, it can be understood that a greater crimping is typically better, with an excess of about 20 crimps per inch being usually preferred. Continuous filament cellulose ester tow, having crimped filaments with approximately 25 to 40 crimps per inch, is commercially available from Hoechst Celanese Corporation, Charlotte, N.C. If desired, an absorbent, superabsorbent pad of multiple layer thickness can be provided. Up to this point, the tow may be, for example, overlapped or overlapped according to conventional procedures. In this way, an absorbent, superabsorbent material of the desired weight and / or thickness can be provided. The specific weight or thickness will depend on factors that include the particular end use. It is especially preferred that the crimped cellulose acetate tow material be opened and then mixed with SAP particles to form the central absorbent layer 284. The SAP can be provided in any particle size, and the appropriate particle sizes They vary greatly depending on the desired final properties. Preferably, a fine particulate is used in the invention instead of a coarse particulate, an SAP having a particle size in the range of about 100 to about 1000 μm. The total basis weights of the absorbent composition 28 including the fibrous materials, SAP, toilet paper, additional layers, and additives are anywhere from about 100-600 grams per square meter. The most preferred total basis weight of the absorbent composition 28, it is from approximately 250 to approximately 350 grams per square meter. Optionally, about 1-10%, and preferably about 5%, by weight of the thermally bonded synthetic fibers in the absorbent composition 28 can be added to impart additional moisture resistance of the composition. This will improve the stability of the core during diaper use. Preferred synthetic fibers are polyolefin / polyester fibers and polyester / polyester bicomponent fibers. Depending on whether it is used wet or dry to manufacture the absorbent composition 28, the attachment of the central absorbent layer 284 with any additional layers and layers of toilet paper 280, 282 can be achieved with hydrogen bonds or adhesive. If the material used to form the absorbent composition 28 comprises about 1-5% by weight of thermally bonded synthetic fibers, the bond can be achieved with thermal bonds. Figures 1A and IB represent only two possible configurations of the absorbent composition 28. In addition to other configurations, additional layers may be present in the absorbent composition. For example, the absorbent composition 28 may include an additional layer, and / or an additional layer may be placed outside of the absorbent composition 28. Any additional layer, including any layer selected from a layer for fluid acquisition, may be used. distribution layer, the additional fibrous layer optionally containing SAP, a capillary layer, a storage layer, or combinations and fragments of those layers. Those layers can be provided to help transfer fluids to the absorbent composition 28, handle fluid surges, prevent rewetting, contain the absorbent material, improve core stability, or for other purposes. For example, a capillary layer having better lateral capillary capabilities can be provided on top of the absorbent composition shown in Figure 3, which has a better absorbency near its side edges. Those skilled in the art are familiar with the various additional layers that may be included in an absorbent article, and the present invention is not intended to be limited to any particular type of materials used for those layers. Rather, the invention encompasses all types of capillary layers, all types of distribution layers, etc., until the types of layers are used. Furthermore any of those additional layers described herein can be used as upper layer 280 and lower layer 282. It is possible in the present invention that absorbent composition 28 be folded when placed between upper sheet 24 and back sheet 26. The absorbent composition 28 may be bent in any suitable manner, including any and all of those described in U.S. Patent No. 6,068,620. Suitable bends include "C" bends, "G" bends, "U" bends, "A" bends, "W" bends or folds, and the like. The invention also relates to a method for manufacturing an absorbent composition and an absorbent article that include providing an upper sheet material 24 and a back sheet material 26. The method also includes preparing an absorbent composition 28 by placing a central absorbent layer comprising a mixture of bast fibers and SAP between the upper layer 280 and the lower layer 282. The method includes placing the absorbent composition 28 between the upper sheet 24 and the back sheet 26. Figure 4 illustrates an apparatus useful for forming an absorbent article. 10 according to the present invention. Figure 4 illustrates the preparation of an absorbent composition using tow fibers. The experts recognize that other fibrous materials can be used to make the absorbent composition 28, and can modify the method and apparatus of Figure 4, specally the forming station of the composition 820, to consider the different types of fibrous material contemplated in the present invention. Any type of fibrous material 285 can be supplied to the apparatus, as shown in Figure 4, any type of tow fibers 285. As is conventional in the art, tow fiber 285 typically opens before forming a fibrous matrix. In this regard, the apparatus includes a tow opener and feeder 810 that is capable of opening any suitable tow material, expanding the tow fiber and feeding the tow fiber to the forming station of the composition 820. It can be used any suitable tow opener and feeder 810 in the method of the invention. The bast fibers 285 are preferably mixed with superabsorbent polymeric material
(SAP) 286 to form the central absorbent layer 284. The
SAP is fed to the core forming station 820 by any SAP 860 feeder capable of feeding the SAP to the core forming station 820. Those skilled in the art are able to design a suitable SAP feeder 860 and the nozzle configuration to provide adequate mixing of the SAP 286 material and the tow fibers 285 to form the central absorbent layer 284. The absorbent composition 28 can be formed at the formation station of the composition 820, where the central absorbent layer 284, comprised of the SAP 286 material and tow fibers 285, is placed between an upper layer 280 and a lower layer 282. The upper and lower layers 280, 282 can be fed to the composition forming unit 820 using any mechanism known in the art. technique, and preferably are fed through one or more feed rollers. An adhesive 295 may be applied to either the upper layer 280 or the lower layer 282, to both layers, or to no layer, by means of an adhesive applicator 840. Again, any mechanism capable of supplying the invention may be used in the invention. an adhesive, in addition to a spray adhesive,
0 one that is "gummed". Suitable adhesives 295 include any adhesives commonly employed in absorbent garments that are useful for adhering one or more toilet tissue materials and / or nonwovens together. It is particularly preferred to use construction adhesives, including HL-1258 by H.B. Fuller Company of St. Paul, Minn .; Findley 2031 and H2587- 01 by Ato Findley Inc. of auwatosa, is .; and NS34-5665 by National Starch Co. of Bridgewater, NJ. Other adhesives that can be used in the invention include 34-578A, available from National Starch Co. of Bridgewater, NJ. Any of these adhesives can be used in all adhesive applications on absorbent garments, or only in selected applications such as a construction adhesive for bonding parts of the garment such as the topsheet, the backsheet, the absorbent core and additional layers. Since the SAP 286 material and the tow fibers 285 are mixed together to form the central absorbent layer 284, which in turn is placed between the upper layer 280 and the lower layer 282 of the formation station of the composition 820 , some of these SAP particles can be fixed in the adhesive 295 when the absorbent composition 28 is passed through one or more pressure rollers 821 in the core forming station 820. The compositions 28 are then cut to length. by the cutting blade 830. The cutting blade 830 can be any suitable cutting device capable of cutting the absorbent composition 28 of the invention. For example, the cutting blade 830 can be comprised of a set of rollers; one being an anvil, and the other having a blade attached at a point on the roller, whereby the diameter of the roller is selected to coordinate with the speed at which the absorbent compositions are formed 28. The knife roller and the roller Anvils can then rotate at the same speed as the linear speed to cut the absorbent composition 28 in selected areas to form compositions of uniform length 28. Those skilled in the art are able to design a suitable cutting blade 830 given the specificity of each article that is formed on the assembly line. The absorbent compositions 28 are then transported to the garment-forming station 800 via the conveyor of the composition 880. The material of the topsheet 24 can be supplied to the garment-forming station 800 by a delivery mechanism of the garment. upper sheet 240, which can be any supply mechanism capable of supplying the upper sheet 24 to the trestir 800 garment forming station. Preferably, the material of the upper sheet 24 is supplied via a supply roll 240 and selected feed rollers or guides. The material of the backsheet 26 can likewise be supplied to the garment-forming station 800 by a delivery mechanism of the backsheet 260, which can be any delivery mechanism capable of supplying the backsheet 26 to the garment forming station 800. Preferably the material of the backsheet 26 is supplied via a supply roll 260 by selected feed or guide rollers. The garment forming station 800 puts together the respective components of the absorbent article 10 by placing the absorbent composition 28 between the material of the topsheet 24 and the material of the backsheet 26. The final absorbent article 10 can then be cut and bent to the appropriate size and shape downstream of the forming station 800. A feature of the present invention is that the absorbent composition 28 comprises a superabsorbent material having an absorbency under Column Load (CAUL) greater than 10 g / g to 0.21 kgf / cm2 (0.3 psi), when subjected to the CAUL test described in detail later. It is preferred that the superabsorbent material 286 has a CAUL greater than 10.7 g / g, more preferably, greater than 11.5 g / g, and more preferably greater than about 12.6 g / g. Another feature of the present invention is that an absorbent garment contains an absorbent core comprising said superabsorbent material. CAUL is a modified version of the Absorbency Under Load (AUL) test described in US Patent 5,147,343, the disclosure of which is incorporated herein by reference in its entirety. AUL measures the ability of a superabsorbent material to swell under an applied force and therefore perform its work. The AUL is expressed as the amount (in millimeters) of an aqueous solution of sodium chloride (0.9 percent by weight of sodium chloride) that can absorb the superabsorbent material per gram in one hour under a load of 21,000 dynes per square centimeter 0.21 kgf / cm2 (approximately 0.3 psi). The AUL test requires a cylinder with an inner diameter of 2.54 cm with a screen of 100 mesh fused to the bottom of the cylinder. After a layer of 0.16 grams of sample of superabsorbent material is placed in the cylinder, a 4.4 gram piston is inserted into the cylinder on top of the sample to apply the required pressure of 0.21 kgf / cm2 (0.3 psi) Which is commonly experienced in infant diapers. The inner part of the screen is then exposed to the solution for one hour. The mass of the liquid absorbed by the superabsorbent material is determined in grams and the AUL is calculated by dividing the mass of the liquid absorbed by the mass of the sample of the superabsorbent material. Although this test is suitable for optimizing the AUL at concentrations of the moderate superabsorbent material it is from about 30% to 45%, where the superabsorbent material is homogeneously mixed in the superabsorbent core, does not address the permeability of the superabsorbent material. In poorly homogenized absorbent compositions, which may occur due to various circumstances such as improper mixing, too much settling, etc., and as the concentration of superabsorbent material in the absorbent compositions increases above 45%, preferably 50% at 95%, greater permeability is desirable. It has not been known until now, however, that the combination of high AUL and high permeability are desirable characteristics in a superabsorbent material. Although the permeability can be tested separately in terms of the absorbance of free volume under load
(FVAUL) or Saline Solution Conductivity (SFC), these tests do not measure the combination of AUL and permeability together. The FVAUL is described in the Patent Application
Serial No. 09 / 685,608 (Absorbent Articles Containing FVAUL High SAP ", the description of which is incorporated herein by reference in its entirety.) Saline Solution Flow Conductivity (SFC) is a measure of the capacity of a material for transporting saline fluid as described in U.S. Patent Nos. 5,562,646 and 6,232,520, the descriptions of which are incorporated herein by reference in their entirety.The AUL Column or CAUL test provides a way to measure both of the AUL and permeability to same time and therefore provides a mechanism for selecting and characterizing SAP materials that have superior performance in an absorbent composition with a high concentration of superabsorbent material as well as in an absorbent composition having a stratified superabsorbent material distribution. larger sample size to provide a sample with height that is approximately eight times higher than the traditional AUL test. This increase in height tests the permeability of the superabsorbent material in addition to the AUL, thus allowing the optimization of these properties. Thus, the CAUL test described herein also considers the gel blockage that can occur when the first particle layer swells and prevents the SAP particles farther from the fluid from coming into contact with the fluid. The invention will now be explained with reference to the following examples.
EXAMPLES The following test procedures were used to determine the values of CAUL for a number of superabsorbent materials used in the absorbent compositions contained in absorbent garments.
Test Procedure for Absorbency under Load in Column (CAUL)
Sample Preparation: CAUL test samples were prepared by spinning a sample container of extreme superabsorbent material on end several times to obtain a representative sample. The superabsorbent material needed to be extracted in a diaper, it was removed carefully without contaminating the sample. The sample of superabsorbent material was then sieved through a 300 to 600 micron mesh. A sample of 2 grams of screened superabsorbent material 520 was then obtained (Figures 5) and placed in a cylinder of CAUL 510. The passage of the sample (SW) was then about 2 grams. The CAUL 510 cylinder was made of Plexiglass with a 512 stainless steel screen fused to one end of the cylinder. The cylinder of CAUL 510 had an internal diameter of 2.5 cm, an external diameter of 3.2 cm and a height of 15 cm. The 512 sieve was 36 micrometers
(400 mesh). The superabsorbent material 520 was evenly distributed without touching the sides of the cylinder 520 before beginning the test. If static was present within the cylinder, a magnetic cloth was used to clean the interior of cylinder 510 before adding sample 520. The sample was placed in the cylinder of CAUL 510 and a cover cover 530 was placed in the CAUL cylinder. 510 on top of the superabsorbent material 520. Then a piston 531 was placed on the top of the cover plate 530 and the assembly 501, including the cylinder 510, the sample 520 has a cover plate 530 and the piston 531, They were heavy. This weight was recorded as the initial weight (IW).
Sample Preparation: Approximately 45 (g) of sodium chloride crystals were weighed in a dry balance dish, and then added together with deionized water to a dry, clean, 5000 ml flask, stopping at the 5000 mark ml. The concentration of the saline solution was measured with a refractometer to ensure a concentration of 0.9%. Then about 10 drops of blue food coloring solution was added to help see the solution during the test, and the solution was poured into a large beaker.
Test Method: A tray 511 was filled for the CAUL test with 0.9% saline solution 540 so that the level was high enough to touch the bottom of the sieve
512 when the assembly 501 was placed in the tray 511. The assembly 501 was placed in the tray 511 and a stopwatch was started simultaneously. The assembly was kept in the tray for 60 minutes. The level of the saline solution in the tray was maintained at a constant level for 60 minutes, so that the superabsorbent material could continuously absorb saline during the entire 60 minute period. After the stopwatch stopped
(after 60 minutes) assembly 501 was removed from tray 511 and weighed again. The weight was recorded as the weight-end (FW). The CAUL was calculated by subtracting the initial weight (IW) from the final weight (FW) and dividing the difference by the weight of the sample (SW), so that the weight of the sample was 2 grams (FW - IW) / SW .
Example 1 Samples A-L and - of CAUL 1-3 High were subjected to the CAUL test described above. Samples A and B were SAP samples extracted from commercially available absorbent garments: Sample A was recovered from a Luvs diaper; and Sample B was recovered from a Huggies Supreme diaper. The C-L samples were from SAP commercially available. Sample C was from BASF P-7710, set 1; 1 Sample D was from BASF P-7710, Lot # 114EID; Sample E was from Sumitomo Seika SA55Sx, Lot 3902125; Sample F was FASF E-1633; Sample G was from BASF E-1610; Sample H was from Nippon Shokubai PX3-W-1090; Sample I was from BASF P-7200; Sample J was from BASF P-7710 (set 1, P0116), Sample K was from BASF E-1609; Sample L was from Stockhausen SP-1287. The CAU1 1-3 Altas samples were SAP samples of ultra high permeability (UHI B-3200 permeability) that were screened for various particle sizes. CAUL 1 High has a particle size of 104 to 850 μm, CAUL 2 High had a particle size of 100 to 300 μm, and CAUL 3 High had a particle size of 600 to 1000 μm. Table and Figure 6 compare the values of the CAUL test for commercially available absorbent materials, and CAUL 1-3 High samples representing the superabsorbent material according to the invention having CAUL values greater than 10 g / g.
Table 1
Other embodiments, uses and advantages of the invention will be apparent to those skilled in the art upon consideration of the specification and practice of the invention described herein. The specification should be considered exemplary only and accordingly it is intended that the scope of the invention be limited only by the following claims.
Claims (41)
- NOVELTY OF THE INVENTION Having described the invention as above, property is claimed as contained in the following: CLAIMS 1. An absorbent article having a longitudinal dimension and a lateral dimension, characterized in that it comprises: a top sheet; a back sheet; and an absorbent composition positioned between the topsheet and the backsheet, wherein the absorbent composition comprises a mixture of fibrous material and superabundant material; wherein the superabsorbent material has an absorbency under load in volume (CAUL) greater than about 10 g / g. The absorbent article according to claim 1, characterized in that the article has a first waist region, a second waist region longitudinally opposed to the first waist region, and a crotch region between the first and second waist regions. , the article further comprises: at least one fastening element attached to a lateral edge of the first waist region; and one or more objective devices attached to the article in the second waist region, wherein at least one fastening element and one or more objective devices are capable of being joined together, with one or more objective devices being located so that the first region of The waist and the second waist region of the garment can be joined together to secure the garment on a wearer. The absorbent article according to claim 2, characterized in that it further comprises elastic leg folds comprising one or more elastic materials placed adjacent a lateral edge of the crotch region, and fixed leg folds placed on the leg. upper sheet adjacent to the lateral edge of the crotch region. The absorbent article according to claim 2, characterized in that at least one fastening element comprises a hook portion of a hook and buckle fastener and one or more objective devices comprises the buckle portion of a hook fastener and buckle. The absorbent article according to claim 2, characterized in that at least one fastening element is an adhesive tape and one or more objective devices comprise a receiving surface of the tape. The absorbent article according to claim 2, characterized in that the at least one fastening element is comprised of a pair of laterally extending tongues placed on the side edges of the first waist region, whereby each of the Laterally extending tabs include at least one fastening element. The absorbent article according to claim 1, characterized in that at least one additional layer is placed between the upper sheet and the rear sheet. The absorbent article according to claim 7, characterized in that at least one additional layer is selected from the group consisting of a fluid acquisition layer, a distribution layer, an additional fibrous layer optionally containing SAP, a capillary layer , a storage layer and combinations and fragments thereof. The absorbent article according to claim 1, characterized in that the absorbent composition comprises an upper layer, a lower layer and a central absorbent layer positioned between the upper layer and the lower layer; wherein the central absorbent layer comprises fibrous material and from about 50% to about 95% by weight of the absorbent material. The absorbent article according to claim 9, characterized in that the fibrous material is at least one bast fiber selected from the group consisting of cellulose acetate fibers, polypropylene fibers, rayon fibers, LYOCELL fibers, fibers of polyacrylonitrile, cotton fibers and cotton fluff fibers. 11. The absorbent article according to claim 9, characterized in that the central absorbent layer further comprises up to 10% by weight of fluff pulp fibers. 12. The absorbent article according to claim 1, characterized in that the fibrous material is a tow of cellulose ester. 13. The absorbent article according to claim 1, characterized in that the fibrous material is a polypropylene tow. The absorbent article according to claim 1, characterized in that the absorbent composition comprises an upper layer, a lower layer, and a central absorbent layer positioned between the upper layer and the lower layer. 15. The absorbent article according to claim 14, characterized in that the upper layer is permeable to fluids, and the lower layer is impermeable to fluids. 16. The absorbent article according to claim 14, characterized in that the upper layer and the lower layer are comprised of the same material, and the material is selected from the group consisting of toilet paper, air-blown fluff pulp, synthetic non-woven material , and mixtures or combinations thereof. 17. The absorbent article according to claim 1, characterized in that the superabsorbent material has a Column Load Absorbency (CAUL) greater than 10.7 g / g. 18. The absorbent article according to claim 1, characterized in that the superabsorbent material has a Column Load Absorbency (CAUL) greater than 11.5 g / g. 19. The absorbent article according to claim 1, characterized in that the superabsorbent material has a Column Load Absorbency (CAUL) greater than 12.6 g / g. 20. An absorbent composition, characterized porgue comprises a mixture of fibrous material and superabsorbent material; where the superabsorbent material has a CAUL greater than 10 g / g. 21. The absorbent composition according to claim 20, characterized in that the superabsorbent material has a CAUL greater than 10.7 g / g- 22. The absorbent composition according to claim 20, characterized in that the superabsorbent material has a CAUL greater than 11.5 g / g 23. The absorbent composition according to claim 20, characterized in that the superabsorbent material has a CAUL greater than 12.6 g / g. The absorbent composition according to claim 20, characterized in that the absorbent composition comprises an upper layer, a lower layer, a central absorbent layer comprising the mixture of fibrous material and superabsorbent material placed between the upper layer and the lower layer. 25. The absorbent composition according to claim 21, characterized in that the central absorbent layer comprises from about 50% to about 95% by weight of superabsorbent material. 26. A method for manufacturing an absorbent composition, characterized in that it comprises preparing a mixture of fibrous material and superabsorbent material; where the superabsorbent material has a CAUL greater than 10 g / g. 27. The method according to claim 26, characterized in that the superabsorbent material has a CAUL greater than 10.7 g / g. 28. The method according to claim 26, characterized in that the superabsorbent material has a CAUL greater than 11.5 g / g. 29. The method according to claim 26, characterized in that the superabsorbent material has a CAUL greater than 12.6 g / g. 30. The method according to claim 26, characterized in that it further comprises: b) preparing an upper layer and a lower layer; and c) depositing the absorbent composition between the upper layer and the lower layer. 31. The method for manufacturing an absorbent article, characterized in that it comprises: a) preparing a top sheet and a back sheet; b) preparing an absorbent composition; bl) preparing a mixture of fibrous material and superabsorbent material; where the superabsorbent material has a CAUL greater than 10 g / g; and c) placing the absorbent composition between the topsheet and the backsheet to form an absorbent article. 32. The method according to claim 31, characterized in that the preparation of the absorbent composition further comprises: b2) preparing a lower layer and an upper layer; and b) placing the absorbent composition between the upper layer and the lower layer. 33. The method according to claim 31, characterized in that the absorbent composition comprises from about 50% to about 95% by weight of the superabsorbent material. 34. The method according to claim 31, characterized in that the fibrous material of the absorbent composition comprises at least one bast fiber selected from the group consisting of cellulose acetate fibers, polypropylene fibers, rayon fibers, LYOCELL fibers. , polyacrylonitrile fibers, cotton fibers and cotton fluff fibers. 35. The method according to claim 31, characterized in that the absorbent composition further comprises up to 10% by weight of fluff pulp fibers. 36. The method according to claim 31, characterized in that the fibrous material is a tow of cellulose ester. 37. The method according to claim 31, characterized in that the fibrous material is a polypropylene tow. 38. A superabsorbent material having a CAUL greater than 10 g / g. 39. The superabsorbent material according to claim 38, characterized in that the superabsorbent material has a CAUL greater than 10.7 g / g. 40. The superabsorbent material according to claim 38, characterized in that the superabsorbent material has a CAUL greater than 11.5 g / g. 41. The superabsorbent material according to claim 38, characterized in that the superabsorbent material has a CAUL greater than 12.6 g / g-
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US10409605 | 2003-04-09 |
Publications (1)
Publication Number | Publication Date |
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MXPA05010836A true MXPA05010836A (en) | 2006-10-17 |
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