Absorbent article having a composite absorbent core

Disclosed is a distinctive composite absorbent core and an absorbent article incorporating the same. The absorbent core comprises at least one absorbent portion and at least one porous resilient portion. The porous resilient portion is located adjacent the absorbent portion and has a wet compression recovery of at least about 85 percent. The porous resilient portion may have a basis weight of from about 50 to about 250 grams per square meter and a density of not more than about 0.050 grams per cubic centimeter. In a particular aspect, the porous resilient portion has a mean pore size of at least about 1.50 millimeters. In a particular aspect, the absorbent article incorporates the absorbent core and has an absorbent core crotch width dimension which may be no more than about 6.35 centimeters. In another particular aspect, the absorbent article also has a fluid intake rate of at least about 10 milliliters per second.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates to an absorbent article having a composite 
absorbent core. The invention more particularly relates to composite 
absorbent cores which have a relatively narrow crotch width for improved 
fit and performance. 
2. Description of the Related Art 
It is desired that absorbent articles such as diapers, training pants or 
incontinence garments both provide a close, comfortable fit about the 
wearer and contain body exudates. Absorbent articles having a relatively 
narrow crotch width have been found to provide an improved fit about the 
wearer which improves the aesthetics of the article and increases the 
wearer's mobility. However, absorbent articles having a narrow crotch 
width commonly fail or leak at the legs before the total absorbent 
capacity of the absorbent article is utilized. Typically, the premature 
leakage at the legs is due to a variety of reasons. For example, 
insufficient distribution of fluid may occur in absorbent articles having 
a narrow crotch width. As such, the relatively small absorbent capacity in 
the crotch portion of such absorbent articles has become saturated with 
fluid and resulted in excessive pooling of the fluid on the bodyfacing 
surface of the absorbent article. The pooled fluid can then leak from the 
leg opening of the absorbent article and soil the outer clothing or 
bedding of the wearer. 
Moreover, insufficient resiliency of the absorbent structure in the narrow 
crotch absorbent articles has resulted in premature leakage around the leg 
openings of the absorbent article when the wearer has exerted compressive 
forces on the absorbent article. For example, conventional absorbent 
structures which generally contain cellulosic fibers and high absorbency 
particles have lost their resiliency and tend to collapse when wetted. The 
collapsed absorbent structure has resulted in a loss in absorbent capacity 
of the absorbent structure due to the loss in void volume. In addition, 
the collapsed absorbent structure has not been able to distribute any 
excess or successive amounts of fluid. 
Attempts to alleviate the leakage of fluid have included providing physical 
barriers such as containment flaps in combination with elastic leg 
gathers. High-absorbency particles have also been included in the 
absorbent structure to increase the fluid holding capacity in various 
regions of the absorbent article. 
However, such attempts have not sufficiently reduced the amount of leakage 
in absorbent articles and, in particular, absorbent articles having a 
narrow crotch width. The addition of containment flaps and elastic leg 
gathers has helped reduce leakage but may result in absorbent articles 
having an increased crotch width that may not provide the proper fit about 
the wearer. Moreover, the use of high-absorbency particles may limit the 
ability of the saturated area of the absorbent structure to distribute any 
excess fluid to the remaining unsaturated areas of the absorbent 
structure. For example, the high-absorbency particles swell as fluid is 
absorbed which may tend to block distribution channels or paths for the 
excess fluid to reach other portions of the absorbent structure. This 
phenomenon is commonly referred to as "gel blocking." The swelling of the 
high-absorbency particles also reduces the void volume of the absorbent 
structure. Further, the high-absorbency particles have typically been 
unable to absorb the fluid exudates at the rate they are excreted from the 
wearer which also has resulted in excessive pooling and leakage. 
Despite the attempts to develop improved absorbent structures, there 
remains a need for absorbent structures which can function in absorbent 
articles having a very narrow crotch width. There is a need for an 
absorbent structure having a very narrow crotch width that can effectively 
distribute fluids such that an increased amount of the absorbent capacity 
of the absorbent structure is utilized. Moreover, there is a need for an 
absorbent structure which has sufficient resiliency, both wet and dry, 
such that it is capable of maintaining sufficient void volume under 
typical loading conditions. 
SUMMARY OF THE INVENTION 
In response to the difficulties and problems discussed above, a new 
absorbent article having a composite absorbent core has been discovered. 
Generally stated, the present invention can provide a distinctive composite 
absorbent core which is suitable for use in an absorbent article. The 
absorbent core comprises at least one absorbent portion and at least one 
porous resilient portion. The porous resilient portion has a void volume 
and is located adjacent the absorbent portion. The porous resilient 
portion also has a wet compression recovery of at least about 85 percent. 
The porous resilient portion may have a basis weight of from about 50 to 
about 250 grams per square meter and a density of not more than about 
0.050 grams per cubic centimeter. In a particular aspect, the porous 
resilient portion has a mean pore size of at least about 1.5 millimeters. 
The composite absorbent core may also include a surge portion. In a 
particular aspect, the composite absorbent core may also have a crotch 
width dimension which is no more than 6.35 centimeters (2.5 inches). 
In another aspect, the present invention can provide a composite absorbent 
core which is suitable for use in an absorbent article. The absorbent core 
has a front section, a back section and a crotch section which extends 
between and connects the front section to the back section. The absorbent 
core comprises a first absorbent portion which is located in the back 
section of the absorbent core and a second absorbent portion which is 
located in the front section and the crotch section of the absorbent core. 
The absorbent core further comprises a first porous resilient portion 
which has a void volume and is located between the first and the second 
absorbent portions. In a particular aspect, the first porous resilient 
portion has a wet compression recovery of at least about 85 percent. 
In another aspect, the present invention can provide an absorbent article 
having a front portion, a rear portion and a crotch portion which extends 
between and connects the front portion to the rear portion. The absorbent 
article comprises an outer cover, a bodyside liner which is superposed on 
the outer cover, and a composite absorbent core which is located between 
the outer cover and the bodyside liner. The absorbent core comprises at 
least one absorbent portion and at least one porous resilient portion 
which has a void volume and is located adjacent the absorbent portion. The 
porous resilient portion has a wet compression recovery of at least about 
85 percent. The absorbent article may have an article crotch width 
dimension which is no more than about 12.7 centimeters (5.0 inches). The 
absorbent article may also include at least one surge portion which may be 
located adjacent the porous resilient portion. In a particular aspect, the 
absorbent article also has a fluid intake rate of at least about 10 
milliliters per second. 
The present invention can advantageously provide an absorbent article 
having an absorbent structure which has a relatively narrow crotch width 
and is capable of efficiently distributing fluids to more effectively 
utilize the absorbent capacity of the absorbent article. The absorbent 
article can provide a conforming, comfortable fit about the wearer while 
sufficiently containing body exudates. A resilient porous component of the 
invention can provide sufficient void volume in the absorbent article and 
more efficiently distribute the fluid to unsaturated areas of the 
absorbent structure of the absorbent article. As a result, the absorbent 
article of the present invention can reduce the amount of leakage around 
the leg openings of the absorbent article even when the width of the 
crotch section of the absorbent article is very narrow.

DETAILED DESCRIPTION OF THE INVENTION 
The present invention provides an absorbent article having a composite 
absorbent core. The composite absorbent core includes at least one 
absorbent portion and at least one porous resilient portion. The absorbent 
article and composite absorbent core may be configured to have a narrow 
crotch width dimension to provide an improved fit about the wearer. 
The absorbent article of the present invention will be described in terms 
of a diaper article adapted to be worn by infants about the lower torso. 
It is understood that the absorbent article of the present invention is 
equally applicable to other articles such as adult incontinent products, 
training pants, feminine care products and the like. Moreover, it should 
be understood that the potential uses of the composite absorbent core of 
the present invention need not be limited to use in absorbent articles. 
For example, the composite absorbent core of the present invention may 
also be used in surgical bandages, sponges and the like. 
FIGS. 1A-1C representatively illustrate an absorbent article 20 of the 
present invention. The surface of the article which contacts the wearer is 
facing the viewer. As representatively illustrated in FIGS. 1A-1C, the 
absorbent article 20 defines a front portion 22, a rear portion 24, and a 
crotch portion 26 connecting the front portion 22 and the rear portion 24. 
The absorbent article 20 includes a bodyside liner 30, an outer cover 32 
and a composite absorbent core 34 located between the bodyside liner 30 
and the outer cover 32. As used herein, reference to a front portion 
refers to that part of the absorbent article which is generally located on 
the front of a wearer when in use. Reference to the rear portion refers to 
the portion of the article generally located at the rear of the wearer 
when in use, and reference to the crotch portion refers to that portion 
which is generally located between the legs of the wearer when in use. 
The crotch portion 26 has opposite longitudinal side portions 28 which 
include a pair of elasticized, longitudinally-extending leg cuffs 36. The 
leg cuffs 36 are generally adapted to fit about the legs of a wearer in 
use and serve as a mechanical barrier to the lateral flow of body 
exudates. The leg cuffs 36 are elasticized by a pair of leg elastics 38. 
The absorbent article 20 further includes a front waist elastic 40 and a 
rear waist elastic 42. The rear portion 24 of the absorbent article 20 
further includes a fastening means 44 which is intended to hold the 
absorbent article 20 about the waist of the wearer when in use. The 
absorbent article 20 may also include a pair of containment flaps 46 which 
extend longitudinally along the absorbent article 20 and are also adapted 
to provide a barrier to the flow of body exudates. It should be recognized 
that individual components of the absorbent article 20, such as the 
elastic members, may be optional depending upon the intended use of the 
absorbent article 20. 
The bodyside liner 30 of the absorbent article 20, as representatively 
illustrated in FIGS. 1A-1C, suitably presents a bodyfacing surface which 
is intended to be worn adjacent the body of the wearer and is compliant, 
soft feeling and nonirritating to the wearer's skin. Further, the bodyside 
liner 30 may be less hydrophilic than the composite absorbent core 34, to 
present a relatively dry surface to the wearer, and may be sufficiently 
porous to be liquid permeable, permitting liquid to readily penetrate 
through its thickness. A suitable bodyside liner 30 may be manufactured 
from a wide selection of web materials, such as porous foams, reticulated 
foams, apertured plastic films, natural fibers (for example, wood or 
cotton fibers), synthetic fibers (for example, polyester or polypropylene 
fibers), or a combination of natural and synthetic fibers. The bodyside 
liner 30 is suitably employed to help isolate the wearer's skin from 
fluids held in the composite absorbent core 34. 
Various woven and nonwoven fabrics can be used for the bodyside liner 30. 
For example, the bodyside liner may be composed of a meltblown or 
spunbonded web of polyolefin fibers. The bodyside liner may also be a 
bonded-carded web composed of natural and/or synthetic fibers. The 
bodyside liner may be composed of a substantially hydrophobic material, 
and the hydrophobic material may, optionally, be treated with a surfactant 
or otherwise processed to impart a desired level of wettability and 
hydrophilicity. In particular embodiment of the present invention, the 
bodyside liner 30 comprises a nonwoven, spunbond, polypropylene fabric 
composed of about 2.8-3.2 denier fibers formed into a web having a basis 
weight of about 22 grams per square meter and a density of about 0.06 
grams per cubic centimeter. The fabric is surface treated with about 0.28 
weight percent of a surfactant commercially available from Rohm and Haas 
Co. under the trade designation Triton X-102. 
The outer cover 32 of the absorbent article 20, as representatively 
illustrated in FIGS. 1A-1C, may suitably be composed of a material which 
is either liquid permeable or liquid impermeable. It is generally 
preferred that the outer cover 32 be formed from a material which is 
substantially impermeable to fluids. For example, a typical outer cover 
can be manufactured from a thin plastic film or other flexible 
liquid-impermeable material. For example, the outer cover 32 may be formed 
from a polyethylene film having a thickness of from about 0.012 
millimeters (0.5 mil) to about 0.051 millimeters (2.0 mils). If it is 
desired to present the outer cover 32 with a more clothlike feeling, the 
outer cover 32 may comprise a polyethylene film having a nonwoven web 
laminated to the outer surface thereof, such as a spunbond web of 
polyolefin fibers. For example, a polyethylene film having a thickness of 
about 0.015 millimeters (0.6 mil) may have thermally laminated thereto a 
spunbond web of polyolefin fibers, which fibers have a thickness of about 
1.5 to 2.5 denier per filament, which nonwoven web has a basis weight of 
about 24 grams per square meter (0.7 ounces per square yard). Methods of 
forming such clothlike outer covers are known to those skilled in the art. 
Further, the outer cover 32 may be formed of a woven or nonwoven fibrous 
web layer which has been totally or partially constructed or treated to 
impart a desired level of liquid impermeability to selected regions that 
are adjacent or proximate the composite absorbent core 34. Still further, 
the outer cover 32 may optionally be composed of a micro-porous 
"breathable" material which permits vapors to escape from the composite 
absorbent core 34 while still preventing liquid exudates from passing 
through the outer cover 32. 
The bodyside liner 30 and outer cover 32 are generally adhered to one 
another so as to form a pocket in which the composite absorbent core 34 is 
located. The bodyside liner 30 and outer cover 32 may be adhered directly 
to each other around the outer periphery of the absorbent article 20 by 
any means known to those skilled in the art such as adhesive bonds, sonic 
bonds or thermal bonds. For example, a uniform continuous layer of 
adhesive, a patterned layer of adhesive, a sprayed or meltblown pattern of 
adhesive or an array of lines, swirls or spots of adhesive may be used to 
affix the bodyside liner 30 to the outer cover 32. Such bonding means may 
also be suitable for attaching other components of the composite absorbent 
core and absorbent article of the present invention together. The leg 
cuffs 36 are suitably formed by portions of the outer cover 32, and/or 
bodyside liner 30, which extend beyond the longitudinal sides of the 
composite absorbent core 34. Naturally, the leg cuffs 36 can also be 
formed from separate materials which are attached to the outer cover 32 
and/or bodyside liner 30. 
The leg cuffs 36, as representatively illustrated in FIGS. 1A-1C, may 
include leg elastics 38. Waist elastics 40 and 42 may also be provided. 
The leg elastics 38 are arranged to draw and hold the absorbent article 20 
against the legs of the wearer. The waist elastics 40 and 42 are also 
arranged to draw and hold the absorbent article 20 against the wearer. 
Materials suitable for use in forming leg elastics 38 and waist elastics 
40 and 42 are known to those skilled in the art. Exemplary of such 
materials are strands or ribbons of a polymeric, elastomeric material 
which are adhered to the absorbent article 20 in a stretched position, or 
which are attached to the absorbent article while the article is pleated, 
such that elastic constrictive forces are imparted to the absorbent 
article 20. In a particular aspect of the invention, the elastics may be 
composed of individual strands of Lycra.RTM. which are available from E. 
I. DuPont de Nemours Co., a business having offices in Wilmington, 
Delaware. It should be noted that leg elastics 38 and waist elastics 40 
and 42 are typically used in conventional absorbent articles to reduce 
leakage which is caused by the inadequacies of the conventional absorbent 
structures and materials. The need for leg elastics 38 and waist elastics 
40 and 42 in the absorbent article of the present invention to help 
prevent leakage may be reduced due to the improved composite absorbent 
core 34. 
The leg elastics 38 and waist elastics 40 and 42 may have any configuration 
which provides the desired performance. For example, the leg elastics 38 
and waist elastics 40 and 42 may comprise a single strand of elastic 
material, or may comprise several parallel or non-parallel strands of 
elastic material. The leg elastics 38 may be generally straight or 
optionally curved to more closely fit the contours of the legs and 
buttocks of the wearer and better contain bodily exudates. The leg 
elastics 38 and waist elastics 40 and 42 may be attached to the absorbent 
article 20 in any of several ways which are well known to those skilled in 
the art. For example, the elastics may be ultrasonically bonded, thermally 
bonded or adhesively bonded to the absorbent article 20. 
The fastening means 44 are typically applied to the corners of the rear 
portion 24 of the absorbent article 20 to provide a means for holding the 
article 20 on the wearer. Suitable fastening means 44 are well known to 
those skilled in the art and can include tape tab fasteners, hook and loop 
fasteners, mushroom and loop fasteners, snaps, pins, belts and the like, 
and combinations thereof. Typically, the fastening means 44 are configured 
to be refastenable. It should also be understood that it may be possible 
to dispense with the fastening means 44 in an absorbent article having a 
given design configuration. 
The composite absorbent core 34, as representatively illustrated in FIGS. 
1A-1C, is positioned between the bodyside liner 30 and the outer cover 32 
to form the absorbent article 20. The composite absorbent core 34 is 
generally conformable and capable of absorbing and retaining body 
exudates. It should be understood that, for the purpose of the present 
invention, the composite absorbent core 34 may comprise a single, integral 
piece of material or, alternatively, may comprise a plurality of 
individual separate pieces of material which are operably assembled 
together. Where the composite absorbent core 34 comprises a single, 
integral piece of material, the material may include the desired 
structural features formed into selected spacial regions thereof. Where 
the composite absorbent core 34 comprises multiple pieces, the pieces may 
be configured as discrete layers or other nonlayered shapes and 
configurations. The pieces or layers may be coextensive or 
non-coextensive, depending upon the requirements of the absorbent article 
20. It is preferred, however, that each of the pieces or layers be 
arranged in an operable, intimate contact with at least one other adjacent 
piece or layer of the absorbent article 20. Preferably, each piece or 
layer is connected to an adjacent portion of the absorbent article 20 by 
suitable bonding means, such as ultrasonic or adhesive bonding, or 
mechanical or hydraulic needling as are well known to those skilled in the 
art. 
FIGS. 2 and 3 representatively illustrate one example of the composite 
absorbent core of the present invention. The composite absorbent core 34 
has a front section 50, a back section 52, a crotch section 54, a 
longitudinal centerline 56 and a transverse centerline 58. The composite 
absorbent core 34 has two generally inwardly bowed lateral edges providing 
a narrow crotch width dimension 64 in the crotch section 54 for 
positioning between the legs of the wearer. When used in an absorbent 
article, such as the absorbent article 20 representatively illustrated in 
FIGS. 1A-1C, the front section 50, back section 52 and crotch section 54 
of the composite absorbent core 34 are located in the front portion 22, 
back portion 24 and crotch portion 26 of the absorbent article 20, 
respectively. As representatively illustrated in FIGS. 2 and 3, the 
composite absorbent core 34 also has at least one absorbent portion 60 and 
at least one porous resilient portion 62. 
The composite absorbent core 34 may have any of a number of shapes and 
sizes. For example, the composite absorbent core may be rectangular, 
I-shaped or T-shaped. The size and absorbent capacity of the composite 
absorbent core 34 should be compatible with the size of the intended 
wearer and the fluid loading imparted by the intended use of the absorbent 
article. In a particular aspect of the invention, the composite absorbent 
core 34 is designed to have an absorbent capacity of at least about 300 
grams of synthetic urine and desirably at least about 400 grams of 
synthetic urine to provide improved performance. The absorbent capacity of 
the absorbent article 20 may be provided entirely by the composite 
absorbent core 34 or may be a greater amount depending upon the 
configuration of the various portions of the absorbent article 20. As used 
herein, the term "absorbent capacity" refers to the absorbent capacity 
value as determined according to the Absorbent Capacity Test as set forth 
in the TEST PROCEDURES section below. 
It is generally preferred that the composite absorbent core 34 be narrower 
in the crotch section 54 of the absorbent core 34 than in the front or 
back section, 50 or 52, respectively. It has been found that the composite 
absorbent core 34 of the present invention is particularly useful when the 
crotch width dimension 64 of the crotch section 54 of the composite 
absorbent core 34 is from about 3.18 to about 6.35 centimeters (1.25 to 
about 2.50 inches), desirably no more than about 5.08 centimeters (2.00 
inches) and more desirably no more than about 3.81 centimeters (1.50 
inches). The narrow crotch width dimension 64 of the crotch section 54 of 
the composite absorbent core 34 allows the absorbent article 20 to 
correspondingly have a narrow overall crotch portion. For example, as 
representatively illustrated in FIGS. 1A-1C, the crotch portion 26 of the 
absorbent article may have an article crotch width dimension 48 which is 
from about 7.62 to about 22.86 centimeters (3.00 to about 9.00 inches), 
desirably no more than about 17.78 centimeters (7.00 inches) and more 
desirably no more than about 12.70 centimeters (5.00 inches). Such a 
narrow article crotch width provides for a better fitting and more 
aesthetically pleasing absorbent article. 
The composite absorbent core 34 of the different aspects of the present 
invention may have a basis weight of from about 500 to about 1200 grams 
per square meter and desirably from about 700 to about 1000 grams per 
square meter for improved performance. 
The absorbent portion 60 of the composite absorbent core 34 may suitably 
comprise various types of wettable, hydrophilic fibrous materials. 
Examples of suitable materials include naturally occurring organic fibers 
composed of intrinsically wettable material, such as cellulosic fibers; 
synthetic fibers composed of cellulose or cellulose derivatives, such as 
rayon fibers; inorganic fibers composed of an inherently wettable 
material, such as glass fibers; synthetic fibers made from inherently 
wettable thermoplastic polymers, such as particular polyester and 
polyamide fibers; and synthetic fibers composed of a nonwettable 
thermoplastic polymer, such as polypropylene fibers, which have been 
hydrophilized by appropriate means known to those skilled in the art. The 
absorbent portion 60 may also comprise selected blends of the various 
types of fibers mentioned above. 
In a particular aspect of the invention, the absorbent portion 60 of the 
composite absorbent core 34 may include a matrix of hydrophilic fibers, 
such as a web of cellulosic fibers, mixed with particles of a 
high-absorbency material such as that commonly known as superabsorbent 
material. As used herein, the term "high-absorbency material" refers to 
materials that are capable of absorbing at least 10 times their own weight 
in liquid. In a particular embodiment, the absorbent portion 60 comprises 
a mixture of superabsorbent hydrogel-forming particles and wood pulp 
fluff. The wood pulp fluff may be exchanged with synthetic, polymeric, 
meltblown fibers or with a combination of meltblown fibers and natural 
fibers. The high-absorbency material may be substantially homogeneously 
mixed with the hydrophilic fibers or may be nonuniformly mixed. The 
high-absorbency material may also be arranged in a generally discrete 
layer within the matrix of hydrophilic fibers. Alternatively, the 
absorbent portion 60 may comprise a laminate of fibrous webs and 
high-absorbency material or other suitable means of maintaining a 
high-absorbency material in a localized area. 
The high-absorbency material can be selected from natural, synthetic and 
modified natural polymers and materials. The high-absorbency materials can 
be inorganic materials, such as silica gels, or organic compounds, such as 
crosslinked polymers. The term "crosslinked" refers to any means for 
effectively rendering normally water-soluble materials substantially water 
insoluble but swellable. Such means can include, for example, physical 
entanglement, crystallined domains, covalent bonds, ionic complexes and 
associations, hydrophilic associations such as hydrogen bonding, and 
hydrophobic associations or Van der Waals forces. 
Examples of synthetic, polymeric, high-absorbency materials include the 
alkali metal and ammonium salts of poly(acrylic acid) and poly(methacrylic 
acid), poly(acrylamides), poly(vinyl ethers), maleic anhydride copolymers 
with vinyl ethers and alpha-olefins, poly(vinyl pyrolidone), poly(vinyl 
morpholinone), polyvinyl alcohol), and mixtures and copolymers thereof. 
Further polymers suitable for use in the absorbent core include natural 
and modified natural polymers, such as hydrolyzed acrylonitrile-grafted 
starch, acrylic acid grafted starch, methyl cellulose, carboxymethyl 
cellulose, hydroxypropyl cellulose, and the natural gums, such as 
alginates, xanthum gum, locust bean gum, and the like. Mixtures of natural 
and w holly or partially synthetic absorbent polymers can also be useful 
in the present invention. 
The high-absorbency material may be in any of a wide variety of geometric 
forms. As a general rule, it is preferred that the high-absorbency 
material be in the form of discrete particles. However, the 
high-absorbency material may also be in the form of fibers, flakes, rods, 
spheres, needles, or the like. Conglomerates of particles of 
high-absorbency material may also be used. An example of a superabsorbent 
polymer suitable for use in the present invention is a superabsorbent 
polymer designated IM5000 which is commercially available from 
Hoechst-Celanese, a business having offices in Portsmouth, Va. 
Other suitable high-absorbency materials may include superabsorbent 
polymers which are commercially available from Dow Chemical Corp., a 
business having offices in Midland, Mich. 
As a general rule, the high-absorbency material is present in the composite 
absorbent core 34 of the present invention in an amount of from about 5 to 
about 95 weight percent and desirably from about 25 to about 80 weight 
percent based on the total weight of the composite absorbent core 34. The 
distribution of the high-absorbency material within the different portions 
of the composite absorbent core 34 can vary depending upon the intended 
end use of the absorbent core 34. 
In a particular aspect of the invention, the absorbent portion 60 comprises 
high-absorbency particles which are distributed within a matrix of 
cellulosic fibers or fluff at an amount of at least about 25 weight 
percent, desirably from about 30 to about 90 weight percent and more 
desirably from about 40 to about 80 weight percent based on the total 
weight of the absorbent portion 60 of the composite absorbent core 34. In 
addition, the absorbent portion 60 may have a density of from about 0.10 
to about 0.40 grams per cubic centimeter and desirably from about 0.15 to 
about 0.35 grams per cubic centimeter. The absorbent portion 60 may also 
have a basis weight of from about 500 to about 900 grams per square meter 
and desirably from about 600 to about 800 grams per square meter. As used 
herein, the term "density" refers to the density of the sample material 
when measured under a load of 0.138 Newtons per square centimeter (0.2 
pounds per square inch). The high-absorbency particles and cellulosic 
fibers may be placed in selected zones of the absorbent portion 60 
depending upon the intended use of the absorbent article 20. For example, 
the high-absorbency particles may be selectively placed in the central 
region of the absorbent portion 60 to reduce the amount of high-absorbency 
particles near the side and end edges of the absorbent portion 60. Such an 
arrangement may provide better containment of the high-absorbency 
particles within the cellulosic fibers. 
As representatively illustrated in FIGS. 2 and 3, the absorbent portion 60 
may include from about 10 to about 22 grams of cellulosic fibers and 
desirably from about 17 to about 21 grams of cellulosic fibers to provide 
improved performance. The absorbent portion 60 may also include from about 
4 to about 9 grams of high-absorbency particles and desirably from about 5 
to about 9 grams of high-absorbency particles. The cellulosic fibers carry 
and position the high-absorbency particles within the composite absorbent 
core 34. A suitable amount of cellulosic fibers and high-absorbency 
particles are incorporated into the absorbent portion 60 such that the 
absorbent portion 60 provides a total absorbent capacity of from about 300 
to about 600 and desirably at least about 400 grams of synthetic urine. In 
a particular aspect, the absorbent capacity of the composite absorbent 
core 34 is substantially provided by the absorbent portion 60. 
As representatively illustrated in FIGS. 2 and 3, the composite absorbent 
core 34 of the present invention also contains a porous resilient portion 
62 to advantageously provide sufficient void volume to improve the overall 
distribution of fluid within the composite absorbent core 34. The improved 
distribution more effectively utilizes the absorbent capacity of the 
composite absorbent core 34. The resilient portion 62 is typically less 
hydrophilic than the absorbent portion 60. The resilient portion 62 is 
also configured to provide resilient void volume to accept and distribute 
fluid surges to remote areas of the absorbent portion 60 even when 
subjected to compressive forces caused by the wearer's position and 
movement. The resilient portion 62 should be both dry resilient and wet 
resilient to maintain sufficient void volume even after initial fluid 
surges. The resilient void volume of the porous resilient portion 62 helps 
prevent fluid exudates from pooling and collecting on portions of the 
composite absorbent core 34 and is particularly useful in composite 
absorbent cores which have a very narrow crotch. 
As representatively illustrated in FIGS. 2 and 3, the porous resilient 
portion 62 may be configured to be in fluid communication with the 
absorbent portion 60 of the composite absorbent core 34. In the 
illustrated embodiment, the porous resilient portion 62 comprises a 
discrete layer which is positioned over the absorbent portion 60. This 
configuration is particularly useful to receive discharged fluids in one 
location of the composite absorbent core 34 and quickly redistribute the 
fluids to other areas of the composite absorbent core 34. 
The porous resilient portion 62 may be of any desired shape and 
configuration. Suitable shapes include, for example, circular, 
rectangular, triangular, trapezoidal, oblong, dog-boned, hourglass-shaped, 
or oval. Desirably, the shape of the porous resilient portion 62 provides 
a sufficient amount of surface area which is in fluid communication with 
the absorbent portion 60. The porous resilient portion 62 has a width 
which is generally from about 50 to about 150 percent and desirably from 
about 100 to about 125 percent of a width of the absorbent portion 60. The 
porous resilient portion 62 may also extend over the entire length of the 
composite absorbent core 34 or may only extend partially along the length 
of the composite absorbent core 34. When the porous resilient portion 62 
is shorter in length than the absorbent core 34, the porous resilient 
portion 70 can be selectively positioned anywhere along the composite 
absorbent core 34. In a particular aspect of the invention, the porous 
resilient portion 62 is approximately centered about the longitudinal 
centerline 56 of the composite absorbent core 34 and positioned primarily 
in the front section 50 and crotch section 54 of the composite absorbent 
core 34. 
Typically, fluid exudates are discharged into the crotch section 54 and a 
portion of the front section 50 nearest the transverse line 58 of the 
composite absorbent core 34. Conventional absorbent structures have become 
saturated in these areas and have thus tended to leak prematurely. The 
problem of premature leakage is even more acute when the crotch section of 
the absorbent structures becomes quite narrow. However, the porous 
resilient portion 62 of the composite absorbent core 34 of the present 
invention reduces the frequency of premature leakage by providing a means 
for the discharged fluid to immediately be distributed to other areas of 
the composite absorbent core 34, such as the region of the front section 
50 of the absorbent core 34 furthest from the transverse line 58 of the 
absorbent core 34 and the back section 52 of the absorbent core 34. 
Various materials can be used to construct the porous resilient portion 62. 
For example, the porous resilient portion 62 may be a nonwoven web of 
fibers, a foam, or any other suitable material which provides the desired 
function. The porous resilient portion 62 may be a substantially 
hydrophobic material and, optionally, can be treated with a surfactant or 
otherwise to impart a desired level of wettability and hydrophilicity. 
If the porous resilient portion 62 is a foam material, any type of polymer 
which can be foamed and which can provide the desired function can be 
used. For example, the porous resilient material 62 may be an open-celled 
foam material made from polystyrene, polyvinylchloride, polyethylene, 
polyolefins, polyurethane, polyisocyanates, polyphenols, epoxy resins, 
silicon resins and the like. The foam material may also be rigid, 
semi-rigid or flexible. In a particular aspect of the invention, the 
porous resilient portion 62 is a semi-rigid, polyurethane open-celled foam 
material. 
Methods of forming such foam materials are well known to those skilled in 
the art. As is well known to tho se skilled in the art, the physical 
properties of the resultant foam materials can be varied broadly by 
controlling the ingredients and processing of the foam materials. 
Following the foaming of the polymer, the structure of the foam can also 
be modified by processes known to those skilled in the art to provide a 
greater number of open cells in the cell structure. For example, the 
percentage of open cells in t he foam material can be increased to as 
great as 99 percent or higher. Foam materials having greater than 95 
percent open cells are generally known as "reticulated" foams. Foam 
materials having an increased number of open cells are particularly 
desired for the porous resilient portion 62 of the composite absorbent 
core 34 of the present invention. In a particular aspect of the invention, 
the porous resilient portion 62 comprises a polyurethane foam material 
wherein at least 80 percent and desirably at least 95 percent of the cells 
present in the foam are open cells. For example, the porous resilient 
portion 62 may include a polyurethane foam material designated Style 
#80,000 Federal Foam which is commercially available from Illbruck, Inc. a 
business having offices located in Minneapolis, Minn. 
In a particular aspect of the invention, the porous resilient portion 62 
has a density (determined at a load of 0.2 psi) which is not more than 
about 0.050 grams per cubic centimeter and desirably from a bout 0.010 to 
about 0.030 grams per cubic centimeter to provide improved performance. 
Desirably, the porous resilient portion 62 also has a basis weight of from 
about 100 to about 200 grams per square meter and more desirably from 
about 125 to about 175 grams per square meter. Moreover, the porous 
resilient portion 62 is desirably substantially free of high-absorbency 
mate rial such as absorbent gelling material such that the porous 
resilient portion 62 does not retain high amounts of fluid. 
The porous resilient portion 62 may also be configured to have a mean pore 
size of at least about 1.50 millimeters and desirably from about 2.0 to 
about 4.0 millimeters. If the mean pore size is too small, the rate of 
fluid intake may be too slow and the distribution of the fluids may not 
effectively use substantially the entire absorbent capacity of the 
composite absorbent core 34. The mean pore size can be determined 
according to any of various methods known to those skilled in the art. One 
such method is the Pore Size Test as set forth in the TEST PROCEDURES 
section below. 
The porous resilient portion 62 of the composite absorbent core 34 of the 
present invention may also be configured to temporarily hold the 
discharged fluid to allow sufficient time for the absorbent portion 60 to 
absorb and contain the fluids. In the different aspects of the present 
invention it is desirable that the porous resilient portion 62 maintain 
sufficient void volume to effectively distribute and temporarily hold the 
discharged fluid. The void volume of the porous resilient portion 62 will 
vary as the load exerted upon it varies. It is particularly important that 
the porous resilient portion 62 be capable of maintaining a sufficient 
amount of void volume even when under load. As used herein, the term "void 
volume" refers to the void volume value as determined according to the 
void volume equation set forth in the Wet Compression Recovery Test in the 
TEST PROCEDURES section below. 
In a particular aspect, the porous resilient portion 62 has a void volume 
which is at least about 20 cubic centimeters per gram and desirably from 
about 30 to about 50 cubic centimeters per gram when under no load. In 
addition, the composite absorbent core 34 can include a sufficient amount 
of the porous resilient portion 62 by weight to provide a void volume of 
at least about 3.0 cubic centimeters and desirably from about 5.0 to about 
9.0 cubic centimeters under no load to provide improved performance. For 
example, the porous resilient portion 62 may include about 0.2 grams of a 
polyurethane foam material having a void volume (under no load) of about 
36 cubic centimeters per gram to provide about 7.2 cubic centimeters of 
void volume when under no load. In a particular aspect, the composite 
absorbent core 34 of the present invention includes from about 5 to about 
20 weight percent and desirably from about 10 to about 15 weight percent 
of the porous resilient portion 62 based on the total weight of the 
composite absorbent core 34 to provide improved performance. 
The porous resilient portion 62 of the composite absorbent core 34 is also 
desirably both wet and dry resilient to preserve the void volume for 
successive fluid surges even after being compressed by the wearer. The 
resiliency of the porous resilient portion 62 may be represented by the 
ability of the material to recover it's original volume after being 
compressed. In a particular aspect, the porous resilient portion 62 has a 
wet compression recovery of at least about 85 percent, desirably from 
about 90 to about 100 percent and more desirably from about 95 to about 
100 percent. As used herein, the term "wet compression recovery" refers to 
the compression recovery value determined according to the Wet Compression 
Recovery Test as set forth in the TEST PROCEDURES section below. It is 
also desirable that the porous resilient portion 62 maintain at least 
about 25 percent, desirably from about 30 to about 100 percent and even 
more desirably from about 50 to about 100 percent of it's void volume 
(under no load) when under a load of 0.673 Newtons per square centimeter 
(0.975 pounds per square inch). 
In another aspect of the invention as representatively illustrated in FIGS. 
4 and 5, the composite absorbent core 34 of the present invention may also 
contain a surge portion 70 to advantageously improve the overall fluid 
intake rate of the composite absorbent core 34. The surge portion 70 is 
typically less hydrophilic than the absorbent portion 60 and is configured 
to collect and temporarily hold fluid surges. This configuration can also 
help prevent fluid exudates from pooling and collecting on portions of the 
composite absorbent core 34. 
Various woven and nonwoven materials can be used to construct the surge 
portion 70. For example, the surge portion 70 may be a layer of a 
spunbonded or meltblown web of polyolefin fibers. The surge portion 70 may 
also be a bonded carded web of natural and synthetic fibers. The surge 
portion 70 may be a substantially hydrophobic material and, optionally, 
can be treated with a surfactant or otherwise to impart a desired level of 
wettability and hydrophilicity. In a particular aspect of the invention, 
the surge portion 70 has a density (determined at a load of 0.2 psi) which 
is not more than about 0.10 grams per cubic centimeter and desirably from 
about 0.04 to about 0.06 grams per cubic centimeter to provide improved 
performance. The surge portion 70 is substantially free of high-absorbency 
material such as absorbent gelling material such that the surge portion 70 
does not retain high amounts of fluid. However, the surge portion 70 may 
contain small amounts of high-absorbency material to help acquire a fluid 
surge. 
As representatively illustrated in FIGS. 4 and 5, the surge portion 70 may 
be configured to be in fluid communication with the absorbent portion 60 
and the resilient portion 62 of the composite absorbent core 34. The surge 
portion 70 may or may not extend the full length of the composite 
absorbent core 34. In the illustrated embodiment, the surge portion 70 
comprises a discrete layer which is positioned over the porous resilient 
portion 62. The surge portion 70 serves to quickly collect and temporarily 
hold discharged fluids and then to eventually release the fluids into the 
porous resilient portion 62 and absorbent portion 60. 
The surge portion 70 may be configured to allow a controlled discharge of 
the liquid exudates such that the liquid exudates remain in the void 
volume of the surge portion 70 for a limited period of time. As such, the 
surge portion 70 may be configured to avoid allowing the liquid exudates 
to simply pass directly through or gush laterally along the plane of the 
surge portion 70. In a particular aspect of the invention, the surge 
portion 70 may be configured to have a mean pore size of from about 0.20 
to about 1.00 millimeters and desirably from about 0.30 to about 0.90 
millimeters as determined according to any of various methods known to 
those skilled in the art such as the Pore Size Test set forth in the TEST 
PROCEDURES section below. If the mean pore size is too small, the rate of 
fluid intake may be too slow and if the effective pore size is too large, 
the fluids may not be retained in the surge portion 70 for a sufficient 
amount of time to allow fluids to be effectively desorbed into the 
absorbent portion 60. 
In the different aspects of the invention as representatively illustrated 
in FIGS. 4 and 5, the surge portion 70 can comprise a nonwoven material 
having a basis weight of from about 30 to about 240 grams per square meter 
and may contain bicomponent fibers. For example, the surge portion 70 may 
include a nonwoven fibrous web which includes about 60 weight percent 
polyester fibers, such as PET fibers which are commercially available from 
Hoechst-Celanese. Suitable bicomponent fibers include a wettable, 
polyethylene/polypropylene bicomponent fiber available from Chisso, Corp., 
a business having offices located in Osaka, Japan. The polyester fibers 
and bicomponent fibers are generally homogeneously bonded together. The 
surge portion 70 may also include other wettable fiber materials such as 
cotton, rayon, wood pulp, inherently wettable synthetic polymers, 
hydrophilized or surface treated polymers and the like. 
The surge portion 70 may be of any desired shape and configuration. 
Suitable shapes include, for example, circular, rectangular, triangular, 
trapezoidal, oblong, dog-boned, hourglass-shaped, or oval. Desirably, the 
shape of the surge portion 70 provides a sufficient amount of surface area 
which is in fluid communication with the absorbent portion 60. The surge 
portion 70 has a width which is generally from about 50 to about 150 
percent and desirably at least about 75 percent of the width of the 
absorbent portion 60 of the composite absorbent core 34. The surge portion 
70 may also extend over the entire length of the composite absorbent core 
34 or may only extend partially along the length of the composite 
absorbent core 34. When the surge portion 70 is shorter in length than the 
absorbent core 34, the surge portion 70 can be selectively positioned 
anywhere along the composite absorbent core 34. In a particular aspect of 
the invention, the surge portion 70 is approximately centered about the 
longitudinal centerline 56 of the composite absorbent core 34 and 
positioned primarily in the front section 50 and crotch section 54 of the 
composite absorbent core 34. 
The different portions of the composite absorbent core 34 of the present 
invention may be selectively designed and configured such that a capillary 
force differential or gradient is created at the interface between each 
portion, such as between the absorbent portion 60 and the porous resilient 
portion 62. The capillary force differential can advantageously improve 
the performance of the composite absorbent core 34. For example, where the 
porous resilient portion 62 is positioned immediately adjacent the 
absorbent portion 60 and the porous resilient portion 62 is designed to 
have a lower capillary attraction as compared to the capillary attraction 
of the absorbent portion 60, then fluids will tend to be desorbed more 
readily from the porous resilient portion 62 into the absorbent portion 
60. To provide the desired difference in capillary attraction, the porous 
resilient portion 62 may be configured to have a larger mean pore size 
than the mean pore size of the section of the absorbent portion 60 which 
is immediately adjacent the porous resilient portion 62. In addition, the 
porous resilient portion 62 can also be configured to be less hydrophilic 
than the absorbent portion 60. 
The composite absorbent core 34 of the different aspects of the present 
invention may be comprised of any suitable combination of absorbent 
portions 60, porous resilient portions 62 and surge portions 70, as 
described above, to provide the desired effectiveness. The porous 
resilient portions 62 may include several different layers which more 
effectively distribute the discharged fluids to remote areas of the 
absorbent portion 60 of the composite absorbent core 34. For example, the 
porous resilient portions 62 may be arranged to provide a "cascading" 
effect on the discharged fluids to increase the displacement and 
distribution of the fluids along the planar surface of the absorbent 
portion 60. 
FIG. 6 representatively illustrates another embodiment of the composite 
absorbent core of the present invention. As representatively illustrated 
in FIG. 6, the composite absorbent core 100 may have a front section 50, a 
back section 52, a crotch section 54, a longitudinal centerline 56 and a 
transverse centerline 58. The composite absorbent core 100 has two 
generally inwardly bowed lateral edges providing a narrow width in the 
crotch section 54 for positioning between the legs of the wearer. As 
representatively illustrated in FIG. 6, the composite absorbent core 100 
includes an arrangement of absorbent portions, porous resilient portions 
and surge portions to provide improved performance. The absorbent 
portions, porous resilient portions and surge portions may be configured 
to be similar to the respective portions described above. 
The various portions of the composite absorbent core 100 can be configured 
in any particular order which provides the desired performance in the 
absorbent article. In a particular aspect of the invention, as 
representatively illustrated in FIG. 6, the composite absorbent core 100 
may include a first absorbent portion 102 and a second absorbent portion 
104. A first porous resilient portion 108 may be positioned between the 
first absorbent portion 102 and the second absorbent portion 104 such that 
the first porous resilient portion 108 is in direct, fluid communication 
with at least one of the first and the second absorbent portions, 102 and 
104 respectively. The first porous resilient portion 108 is configured to 
provide resilient void volume to accept and distribute fluid surges to 
remote areas of both the first and the second absorbent portions 102 and 
104. 
The absorbent portions 102 and 104 and the porous resilient portion 108 may 
be provided by any of the materials discussed above and may be any shape 
or size which provides the desired performance. Each of the different 
portions need not extend the entire length and width of the composite 
absorbent core 100. For example, as representatively illustrated in FIG. 
6, the first absorbent portion 102 may selectively be disposed in the back 
section 52 and crotch section 54 of the composite absorbent core 100 while 
the second absorbent portion may be disposed in the front section 50 of 
the composite absorbent core 100. In this configuration, the first porous 
resilient portion 108 may comprise a layer which extends between the first 
and second absorbent portions 102 and 104 and may or may not extend along 
the entire length and width of the composite absorbent core 100. 
In a particular aspect, the composite absorbent core 100 may further 
include at least one surge portion to advantageously improve the overall 
fluid intake rate of the composite absorbent core 100. For example, as 
representatively illustrated in FIG. 6, the composite absorbent core 100 
may include a first surge portion 112 which is positioned in direct fluid 
communication with the first absorbent portion 102. The composite 
absorbent core 100 may further include a second surge portion 114 which 
extends generally between the first and second absorbent portions 102 and 
104 and is in direct fluid communication with at least one of the 
absorbent portions 102 and 104. 
FIG. 7 representatively illustrates another embodiment of the composite 
absorbent core of the present invention. As representatively illustrated 
in FIG. 7, the composite absorbent core 100 may include a first absorbent 
portion 102, a second absorbent portion 104 and a third absorbent portion 
106. A first porous resilient portion 108 may be positioned between the 
first absorbent portion 102 and the second absorbent portion 104 such that 
the first porous resilient portion 108 is in direct, fluid communication 
with at least one of the first and the second absorbent portions, 102 and 
104 respectively. A second porous resilient portion 110 may be positioned 
between the second absorbent portion 104 and the third absorbent portion 
106 such that the second porous resilient portion 110 is in direct, fluid 
communication with at least one of the second and the third absorbent 
portions, 104 and 106 respectively. The first and second porous resilient 
portions 108 and 110 are configured to provide resilient void volume to 
accept and distribute fluid surges to remote areas of the first, second 
and third absorbent portions 102, 104 and 106. 
The absorbent portions 102, 104 and 106 and the porous resilient portions 
108 and 110 may be provided by any of the materials discussed above and 
may be any shape or size which provides the desired performance. Each of 
the different portions need not extend the entire length and width of the 
composite absorbent core 100. For example, as representatively illustrated 
in FIG. 7, the first absorbent portion 102 may selectively be disposed in 
the back section 52 and crotch section 54 of the composite absorbent core 
100 while the second absorbent portion may be selectively disposed in the 
front section 50 of the composite absorbent core 100. In this 
configuration, the first porous resilient portion 108 may comprise a layer 
which extends between the first and second absorbent portions 102 and 104 
and may or may not extend along the entire length and width of the 
composite absorbent core 100. The third absorbent portion 106 may be 
located underneath the first and second absorbent portions 102 and 104 and 
may extend substantially along the entire length of the composite 
absorbent core 100. The second porous resilient portion 110 may comprise a 
layer which extends between the second and third absorbent portions 104 
and 106 and may or may not extend along the entire length and width of the 
composite absorbent core 100. 
The composite absorbent core 100 as representatively illustrated in FIG. 7 
may further include a first surge portion 112 and a second surge portion 
114 to advantageously improve the overall fluid intake rate of the 
composite absorbent core 100. For example, the first surge portion 112 may 
be positioned in direct fluid communication with the first absorbent 
portion 102 and the second surge portion 114 may be in direct fluid 
communication with at least one of the first, second or third absorbent 
portions 102, 104 or 106. 
It should be understood that the characteristics of each of the similar 
portions, such as the porous resilient portions, may differ when there are 
more than one of the similar portions. For example, as representatively 
illustrated in FIG. 7, the first porous resilient layer 108 may have a 
lower density than the second porous resilient layer 110. 
It has been found that a composite absorbent core having several different 
portions or layers, as representatively illustrated in FIGS. 6 and 7, 
provides improved distribution of fluid exudates to remote areas of the 
absorbent portions, such as absorbent portions 102 and 104. The porous 
resilient portions tend to quickly and evenly distribute the discharged 
fluids and provide resilient void volume while the surge portions enhance 
the overall fluid intake rate of the composite absorbent core 100. The 
fluid exudates tend to be distributed by a "cascading" effect from one 
portion to the next. As opposed to conventional absorbent structures which 
typically have one path for the fluid to travel, the different portions of 
the composite absorbent core 100 provide several different paths for the 
fluids to travel before they are absorbed by the absorbent portions. The 
number and complexity of the different paths along which the fluids can 
travel is dependent upon the number and type or function of the different 
portions incorporated into the composite absorbent core. 
For example, in the composite absorbent core 100 representatively 
illustrated in FIG. 6, the discharged fluids may enter the absorbent core 
100 at the first surge portion 112. The fluids may then pass through the 
first surge portion 112 directly into the first absorbent portion 102, 
into the second surge portion 114, or into the first porous resilient 
portion 108. The portion of the fluids transferred into the second surge 
portion 114 may then be transferred along the second surge portion 114 and 
into the first absorbent portion 102 or, optionally, may pass into the 
first porous resilient portion 108 or into the second absorbent portion 
104. Any fluids transferred into the porous resilient portion 108 may then 
be absorbed by either the first or the second absorbent portions 102 and 
104. 
The relative shape, longitudinal placement and arrangement of the different 
portions of the composite absorbent core of the different aspects of the 
present invention can be selected to provide the best performance 
depending upon the size, age and gender of the wearer. The location of the 
discharge of liquid body exudates from the wearer can vary widely for the 
different categories of wearers. For example, male infants tend to urinate 
towards the front portion of diaper articles while female infants tend to 
urinate closer to the crotch portion of diaper articles. Thus, the 
different portions of the composite absorbent core 34 of the present 
invention can be arranged in many different configurations depending upon 
the typical urination location of the category of wearer. 
The different configuration and properties of the different portions of the 
composite absorbent core of the present invention as representatively 
illustrated in FIGS. 2-7, are designed to provide an improved fluid intake 
rate. As used herein, the term "fluid intake rate" refers to the fluid 
intake rate as determined using the Forced Fluid Intake Test described 
below in the TEST PROCEDURES section. The different portions of the 
composite absorbent core provide sufficient void volume and distribution 
channels to effectively hold fluid discharges and distribute them to 
remote areas of the composite absorbent core thereby increasing the fluid 
intake rate while reducing leakage. In a particular aspect, the composite 
absorbent core and the absorbent article of the present invention are 
configured to have a fluid intake rate of at least about 10 milliliters 
per second, desirably from about 10 to about 40 milliliters per second, 
more desirably from about 20 to about 40 milliliters per second and most 
desirably at least about 25 milliliters per second to provide improved 
performance. 
The different aspects of the present invention can advantageously provide 
an absorbent article having a resilient composite absorbent core which has 
a relatively narrow crotch width and is capable of efficiently 
distributing fluids to more effectively utilize the absorbent capacity of 
the absorbent article. The absorbent article can provide a conforming, 
comfortable fit about the wearer while sufficiently containing body 
exudates. As a result, the absorbent article of the present invention can 
reduce the amount of leakage around the leg openings of the absorbent 
article even when the width of the crotch section of the absorbent article 
is very narrow. 
TEST PROCEDURES 
Absorbent Capacity Test 
The absorbent capacity test measures the amount of fluid which is retained 
in an absorbent article, such as a diaper, or an absorbent core after the 
article or core is loaded with an amount of fluid and an external pressure 
is applied. 
Equipment & Materials 
1. Saturated Capacity (SAT CAP) Tester with Magnehelic vacuum gage and 
latex dam; Tester is described in the Forced Intake and Flowback 
Evaluation (FIFE) test described in U.S. Pat. No. 5,192,606 which issued 
Mar. 9, 1993, to Proxmire et al. 
2. Latex dam, 0.014 inch; Obtain from McMaster-Carr Supply Co., Chicago, 
Ill. 60680-4355. 
3. Teflon coated mesh, 1/4 inch mesh; Obtain from Eagle Supply and Plastic, 
Inc., Appleton, Wis. 54911. 
4. Fiberglass screen, mesh size 18 per inch .times.16 per inch; Obtain from 
a hardware store. 
5. Synthetic Urine; such as synthetic urine available from PPG Industries, 
Appleton, Wis. 
6. Saturation Tub to hold the sample to be tested. 
7. Dry rack, flat, non-corroding of appropriate dimensions to hold the 
sample to be tested. 
8. Balance, 2000 gram capacity and readable to 0.1 gram. 
9. Textile Saw for cutting absorbent core samples. 
10. Scissors 
11. Timer, readable to one second. 
12. Room with standard-condition atmosphere; Temperature=23+1.degree. C. 
(73.4+1.8.degree. F.) and Relative Humidity=50+2%. 
Absorbent Core Only 
Specimen Preparation 
1. Cut the samples to 4.times.4 inches. 
2. Weigh each sample to the nearest 0.1 gram and record the weight on the 
data sheet. 
Testing Procedure 
1. Fill the Saturation Tub with the synthetic urine to a minimum depth of 2 
inches (51 millimeters). 
2. Place the screen on the rack. 
3. Place the samples on the screen at least one inch (25 millimeters) apart 
and submerge the rack and samples in the synthetic urine. 
4. Saturate the samples for a minimum of 20 minutes, but not to exceed 20 
minutes and 15 seconds. 
5. After the samples are saturated, remove the rack, screen and samples 
from the synthetic urine. 
6. Place the screen with the samples on the Saturated Capacity Tester. 
Allow to drip for one minute, then cover the samples with the latex dam 
and adjust the vacuum to 0.5 psi (13.8 inches of water). Hold at this 
pressure for five minutes. 
7. After the five minutes, immediately remove the latex dam from the 
samples and remove the samples from the screen. Weigh the samples to the 
nearest 0.1 gram. 
8. The Absorbent Capacity of the each sample is then calculated thus: 
Absorbent Capacity=Wet weight--Dry weight 
Absorbent Article 
Specimen Preparation 
1. Weigh the article to the nearest 0.1 gram and record on the data sheet. 
2. Cut the elastics on the article to allow it to lie flat. 
Testing Procedure 
1. Fill the Saturation Tub with the synthetic urine to a minimum depth of 2 
inches (51 millimeters). 
2. Place the screen on the rack. 
3. Place the article on the screen with the poly side up and submerge the 
rack and article in the synthetic urine. 
4. Saturate the article for a minimum of 20 minutes, but not to exceed 20 
minutes and 15 seconds. 
5. After the article is saturated, remove the rack, screen and article from 
the synthetic urine. 
6. Place the screen with the article on the Saturated Capacity Tester. 
Allow to drip for one minute, then cover the article with the latex dam 
and adjust the vacuum to 0.5 psi (13.8 inches of water). Hold at this 
pressure for five minutes. 
7. After the five minutes, immediately remove the latex dam from the 
article and remove the article from the screen. Weigh the article to the 
nearest 0.1 gram. 
8. The Absorbent Capacity of the article is then calculated thus: Absorbent 
Capacity=Wet weight--Dry weight 
Wet Compression Recovery Test 
This test has been designed to measure the compression recovery of a 
material when it is wet. The wet compression recovery indicates the 
ability of a material to recover to its original volume after being 
subjected to a compressing force. Wet compression recovery is determined 
from void volume measurements and is measured using an INSTRON or SINTECH 
tensile tester which measures the resisting force as a material is 
compressed between a movable platen and a fixed base at a constant rate 
using a certain amount of force and subsequently releasing the force at 
the same rate. 
Suitable equipment for this test could include: 
Compression tester: 
INSTRON model 6021 with compression test software and 1 kN load cell made 
by Instron of Bucks, England. 
Balance: 
Mettler of Highstown, N.J., model PM4600 
Preferably pressure, or force, and platen position are recorded. If only 
force is recorded, pressure is calculated using: 
##EQU1## 
where: P=pressure in Pascals 
F=force pushing back on the platen in Newtons 
A.sub.P =area of the platen in square centimeters (18.9 cm.sup.2) 
Void volume for a given material is calculated as follows: 
##EQU2## 
where: VV=void volume of the material sample in cubic centimeters per gram 
Vol=volume of the material sample in cubic centimeters 
M=mass of the material sample in grams 
P.sub.fiber =fiber density in grams per cubic centimeter 
For materials made with multiple fiber types, the material fiber density is 
the weight average of each individual fiber density: 
EQU P.sub.fiber, Total =Wt %.sub.fiber 1 .multidot.P.sub.fiber 1 +Wt 
%.sub.fiber 2 .multidot.P.sub.fiber 2 + 
where: 
wt %=weight percent of the fiber type in the material or 
##EQU3## 
When a foam material is being measured, p.sub.fiber is the density of the 
material from which the foam is fabricated. For example, if the foam 
material is a polyurethane foam, p.sub.fiber is the density of 
polyurethane. For foam materials, the void volume (VV) calculated using 
the preceding equation is an approximation and the actual void volume will 
become less than the calculated void volume (VV) as the number of closed 
cells within the foam material increases. 
The void volume of a material will vary as the load upon the material 
varies. The void volume of the material for a given platen position is 
calculated using the void volume equation set forth above wherein: 
Vol=(x.sub.o -x).multidot.A.sub.m .multidot.0.1 cm/mm 
where: 
Vol=volume of material in cubic centimeters 
X.sub.o =initial platen position from the base in millimeters 
x=platen position from initial position in millimeters 
A.sub.m =area of sample material in square centimeters 
The base must be larger in size than the platen. Zero height between platen 
and base distance was set by bringing the platen down until it barely 
touches the base. The platen was then raised to the desired initial height 
from the zero distance. The initial platen position must be greater than 
the initial thickness of the sample material so that the test starts out 
at zero pressure on the sample. The sample material can be the same size 
as the platen or larger. 
For the purpose of measuring wet void volume for the present specification, 
a 4.9 cm diameter circular platen was used to compress materials against 
the base at a rate of 5.08 mm/min up to a 1.32 kg load (6,900 Pascal or 
1.00 lb/in.sup.2 pressure). The platen was then returned at the same rate 
to the initial starting position. The initial starting position for the 
platen was the sample material thickness plus 1 mm from the base. Material 
samples were cut to 50.4 mm diameter circles and were tested in the 
center. Force and position data were recorded at uniform periods of time 
between 0.05 and 0.01 minutes. The test is run on five material samples 
and the results averaged. 
Wet void volume was measured when the material sample was completely 
immersed in 0.9% aqueous saline throughout the test. A flat bottomed 
container such as a hexagonal polystyrene weighing dish catalog #02-202D 
from Fischer Scientific of Pittsburgh, Pa. was placed on the base and the 
platen was zeroed and set to the initial position as described above. A 
0.9% aqueous saline solution was added to the container to fill it to a 
level just to the bottom of the platen at its initial position. An 
appropriate saline could be S/P certified blood bank saline made by 
Stephens Scientific of Riverdale, N.J. and distributed by Baxter 
Healthcare of McGraw Park, Ill. under catalog #B3158-1. For the purpose of 
measuring void volume for the present specifications, 120 ml of saline was 
placed in the container and the platen was initially set a distance equal 
to 1 mm greater than the thickness of the test material sample from the 
base. 
The load cell was tared with this level of fluid in the container. The 
sample was placed in the fluid, under the platen and the test was then 
performed as described above. Buoyant force was found to have a negligible 
effect on pressure but if so desired it can be subtracted from the 
pressure readings at each platen position using the following equation: 
##EQU4## 
where: P.sub.B =Pressure from buoyant force in Pascals 
P.sub.saline =saline (fluid) density in grams per cubic centimeter 
A.sub.P =area of the platen in square centimeters (18.9 cm.sup.2) 
A.sub.d =area of the dish in square centimeters 
X.sub.o =initial platen position from the base in millimeters 
x=platen position in millimeters 
g=standard acceleration of gravity which is 981 cm/seconds.sup.2 
0.01=conversion factor=0.1 cm/mm.multidot.0.001 kg/gm.multidot.100 cm/m 
The overall pressure on the sample becomes: 
EQU P.sub.sample =P.sub.reading -P.sub.B 
where: 
P.sub.sample =pressure on the sample from the platen in Pascal 
P.sub.reading =pressure reading from the SINTECH or INSTRON in Pascal 
P.sub.B =buoyancy pressure from the 0.9% saline in Pascal 
Wet compression recovery was calculated using the platen positions on 
initial compression to 68.9 Pascal and on recovery when the pressure was 
equal to 68.9 Pascal: 
##EQU5## 
where: VV.sub.recovery 68.9 Pa =void volume upon recovery at 68.9 Pascal 
pressure 
VV.sub.compress 68.9 Pa =void volume upon initial compression to 68.9 
Pascal pressure 
Forced Fluid Intake Test 
The apparatus shown in FIGS. 8 and 9 is utilized for this test. This test 
has been designed to measure the fluid intake rate of an absorbent core or 
an absorbent article, such as an infant diaper. The fluid intake rate is 
measured by using a stop watch and visually determining the length of time 
required to absorb simulated urine voidings. The absorbent article is 
prepared by cutting the leg, waist and containment flap elastic members 
every 1" along their length in order to allow the sample to lie flat. The 
absorbent core of the sample may be tested either alone or within the 
absorbent article. 
The sample to be tested is placed in a trough 120 which has an included 
angle, alpha, of 60.degree. such that all of the test liquid is contained 
within the sample 122 by suitable dams placed along the edges of the 
sample. A specified amount of fluid (80 ml) is delivered from a nozzle 124 
having a diameter of 4 millimeters. The fluid is a blood bank saline which 
is commercially available under the trade designation Baxter from Stephens 
Scientific, Inc., a business having offices located in Riverdale, N.J. The 
nozzle 124 is attached to a peristaltic pump equipped with a pulse 
suppressor. The nozzle 124 is placed a distance (b) of 6 millimeters from 
the sample 122 at a distance (c) about 4.5 centimeters from the end of the 
sample and at a perpendicular angle. The fluid is delivered at an average 
rate of 26.7 ml/sec for 3 seconds during each of three insults (80 ml per 
insult). 
The time elapsing between the first fluid contact with the sample and the 
time when the fluid disappears into the sample is measured with a stop 
watch for each insult. The samples are allowed to equilibrate 15 minutes 
between insults. The fluid volume per insult (80 ml) is divided by the 
time elapsed between initial fluid contact and disappearance beneath the 
surface of the sample to determine the fluid intake rate for each insult 
in milliliters per second. 
Pore Size Test 
This test has been designed to measure the mean pore size of a sample of 
material which may be used in an absorbent article, such as an infant 
diaper. The sample of material has a thickness of about 0.25 inches (0.64 
centimeters), a width of about 2.0 inches (5.1 centimeters), and a length 
of about 2.5 inches (6.35 centimeters). The sample is placed on a glass 
microslide having a width of 2.0 inches (5.1 centimeters) and a length of 
3.0 inches (7.62 centimeters). The surface of the sample is coated with a 
2:1 diluted solution of Pentel.RTM. Correction Fluid and isopropyl 
alcohol. The Pentel.RTM. Correction Fluid is commercially available from 
Pentel Co., Ltd., a business having offices located in Japan. The diluted 
solution migrates through the sample and is allowed to dry. The drying 
solution cements the sample to the glass microslide. 
The microslide having the dried, coated sample adhered thereon is placed on 
a macroviewer stand and viewed through a 50 MM El-Nikkor f/2.8 enlarging 
lens. Lighting is provided by an 8-bulb octagonal ring illuminator that 
surrounds the lens to provide "incident darkfield" conditions. The mean 
pore size of the sample of material is determined using a Quantimet 970 
Image Analyzer which is commercially available from Leica Instruments, 
Inc., a business having offices located in Deerfield, Ill. Major cut 
polygons and minor window faces are selected manually with a "light pen" 
when they are approximately orthogonal to the viewing plane. A program was 
developed to analyze the individual measurements and organize them into a 
histogram showing the total number of pores, the mean pore size and the 
standard deviation of the pore size. 
EXAMPLES 
The following examples are presented to provide a more detailed 
understanding of the invention. The particular materials and parameters 
are exemplary and are not intended to limit the scope of the invention. 
EXAMPLE 1 
A medium size diaper suitable for an infant weighing about 13-23 lbs. 
comprised a 1 mil thick outer cover composed of polyethylene film, a 
composite absorbent core of the present invention, and a bodyside liner 
composed of a spunbonded material. The bodyside liner was a nonwoven, 
spunbond, polypropylene fabric composed of about 2.8-3.2 denier fibers 
formed into a web having a basis weight of about 22 grams per square meter 
and a density of about 0.06 grams per cubic centimeter. The bodyside liner 
was surface treated with about 0.28 weight percent of a surfactant 
commercially available from Rohm and Haas Co. under the trade designation 
Triton X-102. 
The composite absorbent core was arranged according to the configuration 
representatively illustrated in FIG. 7 and sandwiched between the outer 
cover and bodyside liner. The first absorbent portion 102 included about 
6.4 grams of wood pulp fluff and 3.4 grams of a high-absorbency material. 
The first absorbent portion had a basis weight of 640 grams per square 
meter and covered an area of 153 square centimeters (23.75 square inches). 
The high-absorbency material was commercially available from 
Hoechst-Celanese under the trade designation IM5000. The second absorbent 
portion 104 included about 3.0 grams of wood pulp fluff and 1.0 grams of 
the IM5000 high-absorbency material. The second absorbent portion had a 
basis weight of 310 grams per square meter and covered an area of 129 
square centimeters (20.0 square inches). The third absorbent portion 106 
included about 6.75 grams of wood pulp fluff and 2.25 grams of the IM5000 
high-absorbency material. The third absorbent portion had a basis weight 
of 310 grams per square meter and covered an area of 290 square 
centimeters (45.0 square inches). 
The first and second porous resilient portions 108 and 110 were composed of 
a polyurethane foam material (Material A) which is commercially available 
under the trade designation Style #80,000 Federal Foam from Illbruck, Inc. 
The first porous resilient portion had a length dimension of 15.2 
centimeters (6.0 inches) and a width dimension of 5.1 centimeters (2.0 
inches) while the second porous resilient portion had a length dimension 
of 20.3 centimeters (8.0 inches) and a width dimension of 5.1 centimeters 
(2.0 inches). 
To determine the wet compression recovery of the first and second porous 
resilient portions, five samples of the polyurethane foam material 
(Material A) were placed in an excess of saline (0.9 weight percent 
solution of sodium chloride in distilled water) and tested according to 
the Wet Compression Recovery Test as described above. The samples were 5 
millimeters thick, had a basis weight of 160 grams per square meter and a 
density of 0.027 grams per cubic centimeter. The samples also had a mean 
pore size of 2.50 millimeters. The wet foam samples had an average 
pre-compression and post-compression void volume of 32.29 and 31.32 cubic 
centimeters per gram and a wet compression recovery of 97.0 percent. The 
results are also tabulated in Table 1 wherein the samples are designated 
Material A. As used herein the term "average" refers to the sum of the 
tested value for two or more samples divided by the total number of 
samples. 
For comparative purposes, two other typical surge materials, Comparative 
Material A and Comparative Material B, were tested according to the Wet 
Compression Recovery Test as described above. Five samples of a first 
through-air bonded carded web surge material (Comparative Material A) were 
placed in an excess of saline (0.9 weight percent solution of sodium 
chloride and distilled water) and tested according to the Wet Compression 
Recovery Test as described above. The first surge material had a basis 
weight of 80 grams per square meter. The first surge material included 60 
weight percent polyester fibers having a denier of about 6,35 weight 
percent polyethylene/polypropylene bicomponent fibers having a denier of 
about 2, and 5 weight percent high bulk polyethylene/polypropylene 
bicomponent fibers. The polyester fibers were PET (polyethylene 
terephthalate) type 295 fibers available from Hoechst-Celanese and the 
polyethylene/polypropylene bicomponent fibers were purchased from Chisso 
Corp., a business having offices in Osaka, Japan. The wet surge material 
samples had an average pre-compression and post-compression void volume of 
53.04 and 39.10 cubic centimeters per gram and a wet compression recovery 
of 73.7 percent. The results are also tabulated in Table 1. 
Five samples of a second through-air bonded carded web surge material 
(Comparative Material B) were also placed in an excess of saline (0.9 
weight percent solution of sodium chloride and distilled water) and tested 
according to the Wet Compression Recovery Test as described above. The 
second surge material had a basis weight of 150 grams per square meter. 
The second surge material included 50 weight percent polyethylene/PET 
sheath-core bicomponent fibers having a denier of about 10 and 50 weight 
percent polyethylene/PET sheath-core bicomponent fibers having a denier of 
about 3. The polyethylene.backslash.PET sheath-core bicomponent fibers 
were purchased from BASF, a business having offices located in 
Ludwigshafen, Germany. The second surge material samples also had a mean 
pore size of 0.740 millimeters. The wet bicomponent surge material samples 
had an average pre-compression and post-compression void volume of 37.29 
and 32.48 cubic centimeters per gram and a wet compression recovery of 
87.1 percent. The results are also tabulated in Table 1. 
TABLE 1 
______________________________________ 
Load Void Volume 
Compression 
(N/cm.sup.2) 
(cm.sup.3 /g) Wet 
Recovery Wet 
______________________________________ 
Material A 
.007 32.29 
.673 11.68 97.0% 
.007 31.32 
Comparative 
.007 53.04 
Material A 
.673 10.85 73.7% 
.007 39.10 
Comparative 
.007 37.29 
Material B 
.673 16.13 87.1% 
.007 32.48 
______________________________________ 
As shown in Table 1, which illustrates the data obtained comparing Material 
A with Comparative Materials A and B, the polyurethane foam material 
(Material A) which can be used to provide the porous resilient portion of 
the different aspects of the present invention has an improved wet 
compression recovery when compared to typical surge materials. 
The first surge portion 112 and second surge portion 114 were similar to 
Comparative Material A as described above except that they had a basis 
weight of 150 grams per square centimeter. The first surge portion 112 and 
second surge portion 114 also had a length dimension of 15.2 centimeters 
(6.0 inches) and a width dimension of 5.1 centimeters (2.0 inches). The 
porous resilient portions and surge portions were substantially centered 
about the longitudinal centerline 56 and transverse centerline 58 of the 
composite absorbent core. The composite absorbent core had a narrow crotch 
width dimension of 3.18 centimeters (1.25 inches). 
The diaper was then subjected to the Forced Fluid Intake Test as described 
above. The diaper had a fluid intake rate of about 32 milliliters per 
second for the first insult (80 ml), about 27 milliliters per second for 
the second insult (80 ml) and about 27 milliliters per second for the 
third insult (80 ml). The results are shown in the graph of FIG. 10. 
Twenty samples of the same diaper were then tested on twenty different 
infants to measure the ability of the diaper to contain fluids prior to 
leaking or overflowing onto the outer clothing of the wearer. The diapers 
were placed on the infants. At five minute intervals, 30 milliliters of 
saline (0.9 weight percent solution of sodium chloride in distilled water) 
was injected into the diaper until the diaper leaked. The net fluid weight 
injected into the diaper (load-at-leak) was then recorded. The leakage 
data is representatively illustrated in FIG. 11. 
EXAMPLE 2 
A medium size diaper suitable for an infant weighing about 13-23 lbs. 
comprised a 1 mil thick outer cover composed of polyethylene film, a 
composite absorbent core of the present invention, and a bodyside liner 
composed of a spunbonded material. The bodyside liner was a nonwoven, 
spunbond, polypropylene fabric composed of about 2.8-3.2 denier fibers 
formed into a web having a basis weight of about 22 grams per square meter 
and a density of about 0.06 grams per cubic centimeter. The bodyside liner 
was surface treated with about 0.28 weight percent of a surfactant 
commercially available from Rohm and Haas Co. under the trade designation 
Triton X-102. 
The composite absorbent core was arranged according to the configuration 
representatively illustrated in FIGS. 2 and 3 and sandwiched between the 
outer cover and bodyside liner. The absorbent portion 60 included about 
10.9 grams of wood pulp fluff and 10.9 grams of a high-absorbency 
material. The absorbent portion had a basis weight of 530 grams per square 
meter and covered an area of 162.6 square centimeters (64.0 square 
inches). The high-absorbency material was IM5000 which was commercially 
available from Hoechst-Celanese. 
The porous resilient portion 62 was the polyurethane foam material 
described in Example 1 as Material A. The porous resilient portion had a 
basis weight of 160 grams per square meter and a density of 0.027 grams 
per cubic centimeter. The porous resilient portion had a length dimension 
of 20.3 centimeters (8.0 inches) and a width dimension of 8.9 centimeters 
(3.5 inches). The porous resilient portion was substantially centered 
about the longitudinal centerline 56 and transverse centerline 58 of the 
composite absorbent core. The composite absorbent core had a narrow crotch 
width dimension of 3.18 centimeters (1.25 inches). 
The diaper was then subjected to the Forced Fluid Intake Test as described 
above. The diaper had a fluid intake rate of about 20 milliliters per 
second for the first insult (80 ml), about 23 milliliters per second for 
the second insult (80 ml) and 13 milliliters per second for the third 
insult (80 ml). The results are shown in the graph of FIG. 10. 
EXAMPLE 3 
A medium size diaper suitable for an infant weighing about 13-23 lbs. 
comprised a 1 mil thick outer cover composed of polyethylene film, a 
composite absorbent core of the present invention, and a bodyside liner 
composed of a spunbonded material. The bodyside liner was a nonwoven, 
spunbond, polypropylene fabric composed of about 2.8-3.2 denier fibers 
formed into a web having a basis weight of about 22 grams per square meter 
and a density of about 0.06 grams per cubic centimeter. The bodyside liner 
was surface treated with about 0.28 weight percent of a surfactant 
commercially available from Rohm and Haas Co. under the trade designation 
Triton X-102. 
The composite absorbent core was arranged according to the configuration 
representatively illustrated in FIGS. 4 and 5 and sandwiched between the 
outer cover and bodyside liner. The absorbent portion 60 included about 
10.9 grams of wood pulp fluff and 10.9 grams of a high-absorbency 
material. The absorbent portion had a basis weight of 530 grams per square 
meter and covered an area of 162.6 square centimeters (64.0 square 
inches). The high-absorbency material was IM5000 which was commercially 
available from Hoechst-Celanese. 
The porous resilient portion 62 was the polyurethane foam material 
described in Example 1 as Material A. The porous resilient portion had a 
basis weight of 160 grams per square meter and a density of 0.027 grams 
per cubic centimeter. The porous resilient portion had a length dimension 
of 20.3 centimeters (8.0 inches) and a width dimension of 8.9 centimeters 
(3.5 inches). 
The surge portion 70 was composed of a through-air bonded carded web 
material which was the same as that described in Example 1 as Comparative 
Material A except that it had a basis weight of 150 grams per square meter 
and a density of 0.056 grams per cubic centimeter. The surge portion also 
had a length dimension of 10.2 centimeters (4.0 inches) and a width 
dimension of 7.6 centimeters (3.0 inches). 
The porous resilient portion and surge portion were substantially centered 
about the longitudinal centerline 56 and transverse centerline 58 of the 
composite absorbent core. The composite absorbent core had a narrow crotch 
width dimension of 3.18 centimeters (1.25 inches). 
The diaper was then subjected to the Forced Fluid Intake Test as described 
above. The diaper had a fluid intake rate of about 20 milliliters per 
second for the first insult (80 ml), about 17 milliliters per second for 
the second insult (80 ml) and about 11 milliliters per second for the 
third insult (80 ml). The results are shown in the graph of FIG. 10. 
EXAMPLE 4 
A medium size diaper suitable for an infant weighing about 13-23 lbs. 
comprised a 1 mil thick outer cover composed of polyethylene film, a 
composite absorbent core of the present invention, and a bodyside liner 
composed of a spunbonded material. The bodyside liner was a nonwoven, 
spunbond, polypropylene fabric composed of about 2.8-3.2 denier fibers 
formed into a web having a basis weight of about 22 grams per square meter 
and a density of about 0.06 grams per cubic centimeter. The bodyside liner 
was surface treated with about 0.28 weight percent of a surfactant 
commercially available from Rohm and Haas Co. under the trade designation 
Triton X-102. 
The composite absorbent core was arranged according to the configuration 
representatively illustrated in FIG. 6 and sandwiched between the outer 
cover and bodyside liner. The first absorbent portion 102 included about 
3.65 grams of wood pulp fluff and 3.65 grams of a high-absorbency 
material. The first absorbent portion had a basis weight of 530 grams per 
square meter and covered an area of 54.0 square centimeters (21.25 square 
inches). The second absorbent portion 104 included about 7.3 grams of wood 
pulp fluff and 7.3 grams of a high-absorbency material. The second 
absorbent portion had a basis weight of 530 grams per square meter and 
covered an area of 108.6 square centimeters (42.75 square inches). The 
high-absorbency material was IM5000 which was commercially available from 
Hoechst-Celanese. 
The porous resilient portion 108 was composed of the polyurethane foam 
material described in Example 1 as Material A. The porous resilient 
portion had a basis weight of 160 grams per square meter and a density of 
0.027 grams per cubic centimeter. The porous resilient portion had a 
length dimension of 20.3 centimeters (8.0 inches) and a width dimension of 
8.9 centimeters (3.5 inches). 
The first surge portion 112 and second surge portion 114 were similar to 
the through-air bonded carded web material described in Example 1 as 
Comparative Material A except that they had a basis weight of 150 grams 
per square meter and a density of 0.056 grams per cubic centimeter. The 
first and second surge portions also had a length dimension of 20.3 
centimeters (8.0 inches) and a width dimension of 8.9 centimeters (3.5 
inches). 
The porous resilient portion and surge portions were substantially centered 
about the longitudinal centerline 56 and transverse centerline 58 of the 
composite absorbent core. The composite absorbent core had a narrow crotch 
width dimension of 3.18 centimeters (1.25 inches). 
The diaper was then subjected to the Forced Fluid Intake Test as described 
above. The diaper had a fluid intake rate of about 17 milliliters per 
second for the first insult (80 ml), about 22 milliliters per second for 
the second insult (80 ml) and about 20 milliliters per second for the 
third insult (80 ml). The results are shown in the graph of FIG. 10. 
Comparative Example 1 
A medium size diaper suitable for an infant weighing about 13-23 lbs. 
comprised a 1 mil thick outer cover composed of polyethylene film, an 
absorbent structure, and a bodyside liner composed of a spunbonded 
material. The bodyside liner was a nonwoven, spunbond, polypropylene 
fabric composed of about 2.8-3.2 denier fibers formed into a web having a 
basis weight of about 22 grams per square meter and a density of about 
0.06 grams per cubic centimeter. The bodyside liner was surface treated 
with about 0.28 weight percent of a surfactant commercially available from 
Rohm and Haas Co. under the trade designation Triton X-102. 
The absorbent structure included about 12.0 grams of wood pulp fluff and 
12.0 grams of a high-absorbency material. The absorbent structure had a 
basis weight of 830 grams per square meter and a density of 0.15 grams per 
cubic centimeter. The high-absorbency material was IM5000 superabsorbent 
material available from Hoechst-Celanese. The absorbent structure was 
sandwiched between the outer cover and bodyside liner. The absorbent 
structure had a narrow crotch width dimension of 3.18 centimeters (1.25 
inches). 
A surge management layer was placed between the bodyside liner and the 
absorbent structure. The surge management layer was composed of a 
through-air bonded carded web material similar to the material described 
in Example 1 as Comparative Material A except that it had a basis weight 
of 150 grams per square meter and a density of 0.056 grams per cubic 
centimeter. The surge layer had a length dimension of 374 centimeters 
(14.75 inches) and a width dimension of 10.2 centimeters (4.0 inches). 
The diaper was then subjected to the Forced Fluid Intake Test as described 
above. The diaper had a fluid intake rate of 6 milliliters per second for 
the first insult (80 ml), 3 milliliters per second for the second insult 
(80 ml) and 2 milliliters per second for the third insult (80 ml). The 
results are shown in the graph of FIG. 10. 
Twenty samples of the same diaper were then tested on twenty different 
infants to measure the ability of the diaper to contain fluids prior to 
leaking or overflowing onto the outer clothing of the wearer. The diapers 
were placed on the infants. At five minute intervals, 30 milliliters of 
saline (0.9 weight percent solution of sodium chloride in distilled water) 
was injected into the diaper until the diaper leaked. The net fluid weight 
injected into the diaper (load-at-leak) was then recorded. The leakage 
data is representatively illustrated in FIG. 11. 
As is shown in FIG. 10, the composite absorbent core and absorbent article 
of the different aspects of the present invention has an improved fluid 
intake rate when compared to typical absorbent articles using conventional 
absorbent structures having similar narrow crotch widths. Further, as is 
illustrated in FIG. 11, the composite absorbent core and absorbent article 
of the present invention are better able to absorb and contain urine upon 
multiple insults. The in-use tests showed significantly improved leakage 
reduction in diapers using composite absorbent cores which include at 
least one porous resilient portion as described above. This data clearly 
demonstrates the desirability of employing porous resilient portions in 
diapers having very narrow crotch widths. 
Thus, the composite absorbent core of the present invention advantageously 
provides a resilient composite absorbent structure which has a relatively 
narrow crotch width and is capable of efficiently receiving and 
distributing fluids to more effectively utilize the absorbent capacity of 
the absorbent article. The narrow crotch width of the absorbent core 
provides an absorbent article having a conforming, comfortable fit about 
the wearer which is also aesthetically pleasing. 
While the invention has been described in detail with respect to specific 
aspects thereof, it will be appreciated that those skilled in the art, 
upon attaining an understanding of the foregoing, may readily conceive of 
alterations to, variations of, and equivalents to these aspects. 
Accordingly, the scope of the present invention should be assessed as that 
of the appended claims and any equivalents thereto.