EMBOSSED ABSORBENT SYSTEMS AND ABSORBENT ARTICLES INCLUDING THE SAME
An absorbent system including an absorbent core with at least one material free zone, at least one central longitudinal extending deep embossed channel, and at least two longitudinal extending deep embossed channels positioned between the material free zone and lateral edges of the absorbent system.
This application claims priority to and the benefit of U.S. Provisional Application No. 63/284,888, entitled ABSORBENT SYSTEMS AND ABSORBENT ARTICLES INCLUDING THE SAME and filed Dec. 1, 2021, the contents of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTIONThe present invention generally relates to embossed absorbent systems, and in particular to embossed absorbent systems useful in hygienic absorbent articles.
BACKGROUNDDiapers, training pants, briefs, sanitary pads and pantiliners have been made and sold for many years. In general, these products prevent accidental contact with body fluids or feces. The products typically include an absorbent core to retain fluids. The cores may be used with acquisition distribution layers (“ADL”) adjacent to, above or below the absorbent core. While generally effective in absorbing liquids, these cores may be thick, stiff, or uncomfortable. There has been a continuing interest in developing improved absorbent cores. In general, there is a desire to improve absorbency, flexibility and comfort.
Absorbent cores with channels or material free zones are known and may provide benefits in terms of fluid handling and product fit. There has also been a desire to improve utilization of the absorbent core and integrity of the absorbent core. Embossed channels have been used to address those concerns. There is a continuing need to provide improved absorbent systems with better use and integrity of the absorbent core.
SUMMARY OF THE INVENTIONAn absorbent system according to an exemplary embodiment of the present invention comprises: an absorbent core comprising at least one material free zone; an absorbent layer above or beneath the absorbent core; an upper core wrap above the absorbent core or absorbent layer; a lower core wrap beneath the absorbent core or absorbent layer; and an acquisition distribution layer above the upper core wrap, wherein the upper core wrap or lower core wrap is attached to the absorbent layer through at least one material free zone of the absorbent core.
An absorbent system according to an exemplary embodiment of the present invention comprises: an absorbent core comprising at least one material free zone; an absorbent layer beneath the absorbent core; an upper core wrap above the absorbent core; a lower core wrap beneath the absorbent layer; and an acquisition distribution layer above the upper core wrap, wherein the upper core wrap does not attach to the absorbent layer through the at least one material free zone of the absorbent core.
An absorbent system according to an exemplary embodiment of the present invention comprises: an absorbent core comprising at least one material free zone; an upper core wrap above the absorbent core; a lower core wrap beneath the absorbent core; a first acquisition distribution layer above the upper core wrap; and a second acquisition distribution layer above the lower core wrap, wherein the upper core wrap does not attach to the lower core wrap through the at least one material free zone of the absorbent core.
An absorbent system according to an exemplary embodiment of the present invention comprises: a first absorbent core comprising at least one material free zone; a second absorbent core comprising at least one material free zone, wherein a size of the at least one material free zone of the second absorbent core is different from a size of the at least one material free zone of the first absorbent core; an acquisition distribution layer between the first and second absorbent cores; and a core wrap surrounding the first absorbent core.
In exemplary embodiments, the absorbent systems of the present invention are embossed with at least one embossed channel extending longitudinally (along the length of the absorbent system) in a middle portion (in some embodiments, centrally between material free zones) of the absorbent system and at least one embossed channel extending longitudinally on outer portions (between material free zones and lateral edges of the absorbent system). In an embodiment, the absorbent system includes two embossed channels extending longitudinally between two material free zones and embossed channels on either side of the material free zones.
An absorbent system according to an exemplary embodiment of the present invention comprises: an absorbent core comprising at least one material free zone; at least one central longitudinal extending embossed channel; and at least two longitudinal extending embossed channels positioned between the at least one material free zone and lateral edges of the absorbent system.
In an exemplary embodiment, the absorbent core comprises two material free zones and two central longitudinal extending embossed channels.
In an exemplary embodiment, the central embossed channels are sinusoidal in shape.
In an exemplary embodiment, the lateral embossed channels are made from a repeating pattern of triangle shaped embossments.
In an exemplary embodiment, the embossed channels are coextensive with a length of the absorbent system.
In an exemplary embodiment, the material free zones comprise an open area of from 5% to 15% of a total area of the absorbent core.
In an exemplary embodiment, the material free zones have a length that is 20% to 80% of a total length of the absorbent core.
In an exemplary embodiment, the absorbent system further comprises a liquid management system below the absorbent core.
In an exemplary embodiment, a length of the liquid management system is greater than a length of the at least one material free zone.
An absorbent product according to an exemplary embodiment of the present invention comprises: a backsheet; a coversheet; and an absorbent system disposed between an upper surface of the backsheet and a lower surface of the coversheet, the absorbent system comprising: an absorbent core comprising at least one material free zone; at least one central longitudinal extending embossed channel; and at least two longitudinal extending embossed channels positioned between the at least one material free zone and lateral edges of the absorbent system, wherein a body facing surface of the backsheet includes elastic strands aligned to pass longitudinally in a central portion of the at least one material free zone.
In an exemplary embodiment, the absorbent product further comprise a liquid management system disposed between an upper surface of the absorbent system and the lower surface of the coversheet.
Absorbent systems according to exemplary embodiments of the present invention include at least one absorbent core or insert having at least one material free zone, and upper and lower core wraps. For the purposes of the present disclosure, the term “material free zone” may be defined as a zone that is intentionally devoid of any material so as to form a void in the absorbent core or insert.
Absorbent cores or inserts may be formed or cut out from rolls of absorbent materials. As used herein, the term “absorbent core or insert” refers to a material or combination of materials suitable for absorbing, distributing, and storing aqueous fluids such as urine, blood, menses, and water found in body exudates. The size and shape of the absorbent core can be altered to meet absorbent capacity requirements, and to provide comfort to the wearer/user. The length of the absorbent core may range from about 20 cm to about 60 cm. The width of the absorbent core may range from about 4 cm to about 20 cm. When a second absorbent core is utilized, the second absorbent core may be the same size as the first core, smaller than the first core, or larger than the first core. The absorbent core suitable for use in the present invention can be any liquid absorbent material known in the art for use in absorbent articles, provided that the liquid absorbent material can be configured or constructed to meet absorbent capacity requirements. Nonlimiting examples of liquid absorbent materials suitable for use as the absorbent core include comminuted wood pulp, which is generally referred to as airfelt; creped cellulose wadding; absorbent gelling materials including superabsorbent polymers, such as hydrogel-forming polymeric gelling agents; chemically stiffened, modified, or cross-linked cellulose fibers; synthetic fibers including crimped polyester fibers; tissue including tissue wraps and tissue laminates; capillary channel fibers; absorbent foams; absorbent sponges; synthetic staple fibers; peat moss; or any equivalent material; or combinations thereof, as is well known in the art of making absorbent products such as sanitary napkins, pantiliners, incontinence pads, and the like. The amount of superabsorbent polymer in the absorbent core may range from about 20 to about 85 or about 40 to about 80 or about 50 to about 75 or about 60 to about 70 percent by weight, based on the total weight of absorbent material in the core.
In exemplary embodiments, the absorbent core may also be a coform material. The term “coform material” generally refers to composite materials comprising a mixture or stabilized matrix of thermoplastic fibers and a second non-thermoplastic material. As an example, coform materials may be made by a process in which at least one meltblown die head is arranged near a chute through which other materials are added to the web while it is forming. Such other materials may include, but are not limited to, fibrous organic materials such as woody or non-woody pulp such as cotton, rayon, recycled paper, pulp fluff and also superabsorbent particles or fibers, inorganic absorbent materials, treated polymeric staple fibers and the like. Any of a variety of synthetic polymers may be utilized as the melt-spun component of the coform material. For instance, in some embodiments, thermoplastic polymers can be utilized. Some examples of suitable thermoplastics that can be utilized include polyolefins, such as polyethylene, polypropylene, polybutylene and the like; polyamides; and polyesters. In some embodiments, the absorbent system includes more than one absorbent core, for example two or three absorbent cores.
At least one absorbent core or insert includes at least one material free zone. As used herein, the term “material free zone” means that an area within the absorbent core is essentially free of absorbent material (and has limited or no absorption capacity). In exemplary embodiments, the at least one material free zone does not contain absorbent material. In an exemplary embodiment, the at least one material free zone is devoid of material of any kind, or is devoid of absorbent material in particular, or is devoid of absorbent material and other types of materials but contains certain other types of materials. The material free zone may be any shape including, but not limited to, round, oval, elliptical, square or rectangular and typically covers an area of from about 5 cm2 to about 20 cm2, and/or from about 5 cm to about 20 cm in length. The width of the material free zone may range from about 0.4 cm to about 2 cm, or from about 0.25 cm to about 1 cm. The material free zone may extend from about 20% to about 80% of the length of the absorbent core. The material free zone typically extends through the thickness of the absorbent core. In some embodiments, the absorbent core has two material free zones. The space between directly adjacent material free zones may range from about 20 mm to about 80 mm or from about 30 mm to about 70 mm or 40 mm, 50 mm or 60 mm. The space between the side edge of the absorbent core and material free zones directly adjacent to the side edge may range from about 10 mm to about 50 mm or from about 20 mm to about 40 mm or about 30 mm. The material free zones create an open area. The open area may range from about 5% to about 15% of the area of the absorbent core. The absorbent core may include three, four, five, six or more material free zones. In embodiments where there is more than one absorbent core, the second and third absorbent cores may or may not include material free zones. When a second or third absorbent core includes at least one material free zone, the size and shape of the material free zone(s) may be the same as the material free zone(s) in the first absorbent core or may be different.
In exemplary embodiments, the absorbent system may include an acquisition distribution layer (ADL) for distributing liquids to the fluid-absorbent core. The ADL may be made entirely of conventional fibrous materials with little absorbency, but in some embodiments includes water-absorbent polymer particles or other absorbent materials. The fibrous material may be hydrophilic, hydrophobic or can be a combination of both hydrophilic and hydrophobic fibers. The fibrous material may be derived from natural fibers, synthetic fibers or a combination of both. Suitable ADLs are formed from cellulosic fibers and/or modified cellulosic fibers and/or synthetics or combinations thereof. Thus, suitable ADLs may contain cellulosic fibers, in particular wood pulp fluff. Modified cellulosic fibers may be utilized for fluid acquisition and distribution. Examples of modified cellulosic fibers are chemically treated cellulosic fibers, especially chemically stiffened cellulosic fibers. The basis weight of cellulosic fibers and modified cellulosic fibers may range from about 50 to about 200 gsm.
Suitable acquisition-distribution layers may further include synthetic fibers. Hydrophilic synthetic fibers may be obtained by chemical modification of hydrophobic fibers, such as by surfactant treatment of hydrophobic fibers. The surface of the hydrophobic fiber can be rendered hydrophilic by treatment with a nonionic or ionic surfactant, e.g., by spraying the fiber with a surfactant or by dipping the fiber into a surfactant.
In an embodiment, two separate ADLs, each including an absorbent layer and a synthetic fiber layer, may together form a liquid management system (“LMS”). The ADLs may be longer than the material free zones of the absorbent core. For example, the ADLs may be the length of the material free zone plus 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 100% or more of the length of the material free zones. The absorbency of a lower layer of each ADL may be 50% to 100% greater than the absorbency of an upper layer of the ADL. The upper layer may provide vertical wicking (moving fluid down to the absorbent layer). Both ADLs may have basis weights less than 100 gsm, for example 90, 80, 70, 60, 50, 40, 30 or 20 gsm.
In some embodiments, acquisition-distribution layers comprise fibrous material and water-absorbent polymer particles distributed within to function as an absorbent layer. ADLs may include from about 80% to about 100% by weight fibrous material and from 0% to about 20% or about 5% to about 15% or about 10% by weight water-absorbent polymer particles, based on the total weight of the ADL. An ADL functioning as an absorbent layer may be placed above or below the absorbent core. When above the absorbent core, the absorbent ADL may be attached through the material free zone to the lower core wrap. When below the absorbent core, the absorbent ADL may be attached through the material free zone to the upper core wrap. The absorbent ADL may not be attached to the core wrap. The non-absorbent ADL may also be placed above the absorbent core or below the absorbent core and either attached or not attached to the core wrap.
Alternatively, a bundle of synthetic fibers acting as an ADL loosely distributed on top of or below the fluid-absorbent core may be used. Suitable synthetic fibers include, for example, copolyester, polyamide, copolyamide, polylactic acid, polypropylene or polyethylene, viscose or blends thereof. Bicomponent fibers may also be used. In exemplary embodiments, the synthetic fiber component may be composed of either a single fiber type with a circular cross-section or a blend of two fiber types with different cross-sectional shapes.
The ADL basis weight may range from about 20 gsm to about 200 gsm, depending on the concentration of water-absorbent polymer particles. The length of upper ADLs may range from about 6 cm to about 25 cm. The width of upper ADLs may range from 4 cm to 10 cm. The length of lower ADLs may range from about 6 cm to about 60 cm. The width of lower ADLs may range from 6 cm to 15 cm.
In exemplary embodiments, a core wrap may assist with containment and integrity of the absorbent core components. The core wrap may be bonded to the absorbent core. Bonding of the core wrap to the absorbent core may occur via any means known to one of ordinary skill, such as, but not limited to, adhesives. The core wrap may be composed of separate sheets of material (such as an upper core wrap and a lower core wrap) which can be utilized to partially or fully encompass the absorbent core and which can be sealed together using a sealing means such as an ultrasonic bonder or other thermochemical bonding means, or the use of an adhesive. The core wrap may include, but is not limited to, natural and synthetic fibers such as polyester, polypropylene, acetate, nylon, polymeric materials, cellulosic materials such as wood pulp, cotton, rayon, viscose, LYOCELL® such as from Lenzing Company of Austria, or mixtures of these or other cellulosic fibers, and combinations thereof. Natural fibers may include wool, cotton, flax, hemp, and wood pulp. The material forming the core wrap may be selected from meltblown-spunbond-meltblown fabric, spunbond fabric, meltblown fabric, coform fabric, carded web, bonded-carded web, bicomponent spunbond fabric, spunlace, tissue, and combinations thereof. Further, the core wrap may be made of a spunbond-meltblown-spunbond (“SMS”) material, such as a 9 gsm spunbond-meltblown-spunbond material.
The core wrap may be less hydrophilic than the absorbent core, but sufficiently porous to permit body fluids to penetrate through the core wrap to reach the absorbent core. The core wrap may have sufficient structural integrity to withstand its own wetting and the wetting of the absorbent core. In order to support this functional property of the core wrap, a wet strength agent may be applied to the core wrap. A non-limiting example of a wet strength agent may be Kymene 6500 (557LK) or equivalent available from Ashland Inc. of Ashland, Ky., U.S.A. Similarly, a surfactant may be included in the core wrap to promote hydrophilicity.
The upper and lower core wraps may be attached at the sides adjacent to the core (sandwich attachment) or in a C wrap configuration. With the C wrap configuration, the upper core wrap may fold around and under the bottom of the core, where it is attached to the lower core wrap. Alternatively, the lower core wrap may fold around and over the upper of the core, where it is attached to the upper core wrap. In some embodiments, the absorbent system does not include a core wrap.
In exemplary embodiments, the absorbent system is embossed sufficiently by a process referred to herein as “deep embossing” to provide enhanced utilization of absorbent material and structural integrity to the core. In exemplary embodiments, at least one deep embossed channel is positioned centrally extending longitudinally. Embossing is typically performed with the product passed between two rolls. One roll may be smooth while the other roll has emboss or deboss patterns extending out from (deboss) or into (emboss) the surface. Pressure on the surface of the product and heat results in the emboss or deboss pattern transferred to the product. In exemplary embodiments, at least one deep embossed channel is positioned laterally extending longitudinally. The deep embossed channels may be any shape including, but not limited to straight lines, circles, crosshatches, sinusoidal lines, triangles, hearts or combinations thereof. The length of each deep embossed channel may be co-extensive with the length of the absorbent system or shorter. For example, the length of the deep embossed channel may be 40%, 50%, 60%, 70%, 80%, 90% or 100% of the length of the absorbent system. Each deep embossed channel may be the same length as the other, or the length of the deep embossed channels may vary. The deep embossed channel may have a width of from about 1 mm to about 10 mm or from about 2 mm to about 8 mm or from about 3 mm to about 6 mm or 5 mm. The depth of the deep embossed channel is sufficient to provide improved liquid movement laterally and/or longitudinally and to improve core integrity. The depth of the embossed channel may range from about 20% to about 30%, 40%, 50%, 60%, 70%, 80%, 90% or 100% of the thickness of the absorbent system.
In an exemplary embodiment, the absorbent system has two material free zones. One or two deep-embossed channels are created equidistant and centrally between the material free zones. A deep embossed channel is also created between each side edge of the material free zone and lateral edge of the absorbent system.
The absorbent systems may be useful for, for example, diapers, training pants, youth pants, briefs, sanitary pads, bladder control pads and the like. In use, the absorbent systems of exemplary embodiments of the present invention are placed on a top surface of a backsheet. Backsheets are materials that generally are liquid impermeable but may be moisture vapor permeable (breathable). Backsheets are used in absorbent products on a surface of the product that is distal to the user's body. The backsheet can be made of any known or otherwise effective backsheet material, provided that the backsheet prevents external leakage of exudates absorbed and contained in the protective underwear. Flexible materials suitable for use as the backsheet include, but are not limited to, woven and nonwoven materials, laminated tissue, polymeric films such as thermoplastic films of polyethylene and/or polypropylene, microporous films, composite materials such as a film-coated nonwoven material, or combinations thereof, as is well known in the art of making absorbent products, such as sanitary napkins, pantiliners, incontinence pads, and the like.
Backsheets may include a single layer or multiple layers. An outer layer may be soft nonwoven materials while an inner body facing layer may be polymer film. The backsheet may be breathable. The backsheet may include elastic strands in the longitudinal direction (along the length of the product) to provide improved convex or outward curvature of the product, which provides increased spatial separation of the topsheet or body side liner of the article from the genital area. The elastic strands may have elongation of from 50% to 200% of the relaxed length of the strands. Elastic strands, such as LYCRA brand and the like may be attached to a body facing surface of the backsheet with adhesive, thermal bonding, ultrasonic bonding and the like. Alternatively, the elastic strands may be attached to the polymer film facing surface of the nonwoven or the nonwoven facing surface of the polymer film. Spacing between elastic strands may range from 5 mm to 30 mm or more, for example 10, 15, 20, 25 or 35 mm. The elastic strands are typically applied under tension to help the product fit better and reduce sagging. In an embodiment, elastic strands are aligned such that strands overlap open areas of the material free zones of the absorbent core (preferably in the central portion of the material free zones).
The absorbent system is typically attached to the backsheet with an adhesive. Suitable adhesives are known in the art and include hot melt adhesives, emulsion polymer adhesives and the like.
A topsheet or cover is placed on top of the absorbent system and attached to the core or insert and backsheet with adhesive, ultrasonic bonding or combinations thereof, forming a chassis. Suitable topsheets are compliant, soft feeling, and non-irritating to the body of the wearer. Suitable topsheet materials include a liquid pervious material that is oriented towards and contacts the body of the wearer, thereby permitting body discharges to rapidly penetrate through the topsheet without allowing fluid to flow back through the topsheet to the skin of the wearer. A suitable topsheet can be made of various materials, such as woven and nonwoven materials; apertured film materials including apertured formed thermoplastic films, apertured plastic films, and fiber-entangled apertured films; hydro-formed thermoplastic films; porous foams; reticulated foams; reticulated thermoplastic films; thermoplastic scrims; or combinations thereof, as is well known in the art of making absorbent products such as sanitary napkins, pantiliners, incontinence pads, protective underwear and the like.
Elastic side panels may be attached to the chassis to form diapers or adult protective underwear. Any elastic side panel known in the art of absorbent articles may be useful. Suitable elastic side panels include laminates of elastic films with nonwovens, laminates of elastic strands with nonwovens and the like. The elastic panels may be attached to the chassis by adhesive, ultrasonic bonding or a combination thereof. The length, width and shape of the side panels may be designed to make products of different sizes. Products with side panels may have a more underwear like appearance.
The side panels are then attached to the insert/core. A portion of each side panel is left unattached to form leg openings. The side panels may be attached to the insert/core with glue, adhesive, ultrasonic bonding or combinations thereof. The side panels may be attached to the insert/core at various angles to create a more garment like fit.
As is known in the art, hooks and loops may be used on articles in accordance with exemplary embodiments of the present invention. Nonwoven materials may function as the loops.
In exemplary embodiments, the hook fasteners may be made up of separate hook elements or may be integral with the side panels. In this regard, the hook elements may be bonded to the side panels by adhesive, ultrasonic, thermal bonding or the like. Alternatively, the hook elements may be intimately joined with the material that forms the side panels. Such intimate bonding of hook elements with a layer of material may be accomplished by feeding extruded plastic and a sheet of material through a nip formed by a first roller having pins and a second roller having corresponding cavities. As the molten plastic is forced through the nip, it flows into the cavities of the second roller and also into pores in the sheet of material. The plastic in the cavities cools and hardens so as to form a hook sheet. At the same time, the sheet of material is intimately joined to and becomes an integral part of the hook sheet so as to form a laminated structure. This process is disclosed in U.S. Pat. No. 5,518,795, the contents of which are incorporated herein by reference in their entirety. The hook elements may be arranged on the side panels in longitudinally extending strips that are laterally spaced from one another. Alternatively, the hook elements may be arranged in a pattern of geometric shapes or lines. Desirably, the hook elements are arranged on an inelastic material in order to improve ease of processing and the shear strength of the seam.
In exemplary embodiments, absorbent systems of the present invention provide absorbent products with absorbency, fit, core integrity, improved utilization of absorbent material and comfort.
Conventional absorbent core machines for making diapers and protective underwear may be modified with a kit to make products according to exemplary embodiments of the present invention.
Now that embodiments of the present invention have been shown and described in detail, various modifications and improvements thereon can become readily apparent to those skilled in the art. Accordingly, the exemplary embodiments of the present invention, as set forth above, are intended to be illustrative, not limiting. The spirit and scope of the present invention is to be construed broadly.
Claims
1. An absorbent system comprising:
- an absorbent core comprising at least one material free zone;
- at least one central longitudinal extending embossed channel; and
- at least two longitudinal extending embossed channels positioned between the at least one material free zone and lateral edges of the absorbent system.
2. The absorbent system of claim 1, wherein:
- the absorbent core comprises two material free zones and two central longitudinal extending embossed channels.
3. The absorbent system according to claim 2, wherein the central embossed channels are sinusoidal in shape.
4. The absorbent system according to claim 3, wherein the lateral embossed channels are made from a repeating pattern of triangle shaped embossments.
5. The absorbent system according to claim 4, wherein the embossed channels are coextensive with a length of the absorbent system.
6. The absorbent system according to claim 2, wherein the material free zones comprise an open area of from 5% to 15% of a total area of the absorbent core.
7. The absorbent system according to claim 2, wherein the material free zones have a length that is 20% to 80% of a total length of the absorbent core.
8. The absorbent system according to claim 1, further comprising a liquid management system below the absorbent core.
9. The absorbent system according to claim 8, wherein a length of the liquid management system is greater than a length of the at least one material free zone.
10. An absorbent product comprising:
- a backsheet;
- a coversheet; and
- an absorbent system disposed between an upper surface of the backsheet and a lower surface of the coversheet, the absorbent system comprising: an absorbent core comprising at least one material free zone; at least one central longitudinal extending embossed channel; and at least two longitudinal extending embossed channels positioned between the at least one material free zone and lateral edges of the absorbent system,
- wherein a body facing surface of the backsheet includes elastic strands aligned to pass longitudinally in a central portion of the at least one material free zone.
11. The absorbent product according to claim 10, further comprising a liquid management system disposed between an upper surface of the absorbent system and the lower surface of the coversheet.
Type: Application
Filed: Jul 7, 2022
Publication Date: Jun 1, 2023
Inventors: Susan O'Connell (Chesterbrook, PA), Berna Yalcin (King of Prussia, PA), Brian K. Dyer (Gray, GA), Mickey Wesley Calvert (Bowling Freen, KY)
Application Number: 17/859,200
