Abstract: In accordance with the present invention, a composite absorbent structure is formed by air laying an absorbent core comprising cellulosic fibers, typically wood pulp fibers. The absorbent core may include superabsorbent polymeric material (SAP), for enhanced liquid absorption and retention. The present invention contemplates that a nonwoven fabric layer be provided which comprises polymeric fibrous material, either in staple length or filamentary form. A composite material is formed in which the cellulosic fibers are hydrogen bonded to form an absorbent core and the nonwoven fabric layer is laminated to this hydrogen bonded layer, without adding additional non-cellulosic bonding agents (the cellulosic fibers themselves act as their own bonding agents) either to the cellulosic layer or between the cellulosic layer and the nonwoven.

Abstract: An absorbent material is provided with improved characteristics. A process is provided for making the absorbent material. A web is formed with at least one layer of absorbent material, and it may include a mixture of cellulosic fibers and superabsorbent material. The moisture content of the web is increased so as to increase the web density. Then, the web is compacted at an elevated temperature to further increase the web density and preferably to also effect hydrogen bonding within the web. In one embodiment a tissue layer is provided, is wetted with water, and is bonded to the layer of absorbent material.

Abstract: Multilayered absorbent cores are provided that include synthetic fiber to improve the liquid transport properties of the resulting absorbent articles. The synthetic fiber, which may be found in either the innermost and/or intermediate layers of the absorbent core, particularly improve the rewet performance of the absorbent article. The absorbent cores may be incorporated into a number of absorbent articles, including diapers, feminine hygiene products and incontinence pads.

Abstract: A process is provided for making a soft, high density, absorbent material with improved characteristics. A web is formed from material that includes a mixture of cellulosic fibers and synthetic polymer fibers. Then, the web is preferably compacted and embossed at an elevated temperature to further increase the web density and preferably to also create liquid-stable bonds between the synthetic polymer fibers and the cellulosic fibers in spaced-apart regions of the web.

Abstract: A method for formation of shaped components such as shaped absorbent cores, for disposable absorbent articles, contemplates that a relatively wide web of material be provided from which the components are cut. The web of material is longitudinally slit to form a plurality of subdivided webs each having shaped components arranged in serial relationship. The shaped components of adjacent ones of the subdivided webs are nested with each other, that is, a line extending longitudinally of the web extends through the components of adjacent subdivided webs. Efficient formation is facilitated by collecting the marginal portions of the web of material, and at least partially recycling the collected portions for formation of the wide web.

Abstract: A soft, high density, absorbent material is provided with improved characteristics. A process is provided for making the absorbent material. A web is formed from material that includes a mixture of cellulosic fibers and synthetic polymer fibers. Then, the web is preferably compacted and embossed at an elevated temperature to further increase the web density and preferably to also create liquid-stable bonds between the synthetic polymer fibers and the cellulosic fibers in spaced-apart regions of the web.

Abstract: Soft wood pulp sheets, soft absorbent cores, and methods for making the soft wood pulp sheets or soft absorbent cores by addition of non-ionic plasticizers before, during or after the pulp or core manufacturing process are disclosed. Preferred non-ionic plasticizers are ethers or esters such as triacetin, citrates or glycol derivatives.