Patent Publication Number: US-2012041405-A1

Title: Absorbent article including a formed fibrous article

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application is a continuation application of U.S. patent application Ser. No. 12/866,175, filed Aug. 12, 2010, priority of which is hereby claimed. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to a method and apparatus for a making a formed fibrous article and more specifically to method and apparatus for making a formed fibrous article useful as an absorbent core structure in a disposable sanitary article such as a sanitary napkin, panty liner, diaper or the like. The present invention also relates to a disposable sanitary article including a formed fibrous article according to the present invention as a core structure thereof. 
     BACKGROUND OF THE INVENTION 
     Various methods for making formed fibrous articles from fibrous materials such as cellulose or the like are well know to those of skill in the art. One common method of manufacturing such formed fibrous articles consists of defiberizing a starting material and then creating an air-entrained stream of the defiberized material. The air-entrained defiberized material may be formed into a formed fibrous article through the use of a porous mold structure subjected to a vacuum to draw the defiberized material into the mold. 
     It is also known that formed fibrous articles of the type described above may be subjected to calendering processes to alter the mechanical and fluid handling properties of such articles. A calendering process used in the art is commonly referred to as “pin calendering”. Pin calendering employs the use of a plurality of pins adapted to compress and densify the article. 
     A problem associated with pin calendering processes of the type described above is that such processes typically require that a “carrier layer” be used during the pin-calendering step. “Carrier layer” as used herein means any material layer used to support the formed fibrous article, such as a conveyer belt or an adjacent material layer such as rolled nonwoven layer or the like. The use of a carrier layer increases complexity of manufacture. In addition, if the carrier layer is a layer intended to be incorporated into the final product, the inclusion of such layer may increase the cost of the final product and/or undesirably affect the fluid handling characteristics of the product. 
     In view of the above the inventors of the present invention have discovered, and disclosed herein, a method and apparatus for making a pin-calendered formed fibrous article that does not require the use of a carrier layer. Formed fibrous articles according to the present invention are particularly useful as an absorbent core structure in a disposable sanitary article such as a sanitary napkin, panty liner, diaper or the like. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing, the present invention provides an absorbent article including a liquid permeable cover layer, a liquid impermeable barrier layer, a formed fibrous article arranged between the cover layer and the barrier layer, wherein the formed fibrous includes a planar portion and a first and second raised area extending upwardly from the planar portion, a region located between the first raised area and the second raised area, the planar portion and the first and second raised areas being both formed from a common material composition having a constant basis weight, the planar portion having a different thickness and density than each of the first raised area and second raised area, wherein the cover layer extends over the first raised area, the second raised area, and region located between the first raised area and the second raised area, and wherein a portion of the cover layer extending over the region located between the first raised area and the second raised area is arranged in spaced relationship to the formed fibrous article. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Examples of embodiments of the present invention will now be described with reference to the drawings, in which: 
         FIG. 1  is a side elevation view of an apparatus according to the present invention; 
         FIG. 2  is a detailed perspective view of the forming drum that forms part of the apparatus according to the present invention; 
         FIG. 3  is a sectional view taken along line  3 - 3  in  FIG. 2 ; 
         FIG. 4  is a detailed perspective view of a portion of the forming drum shown in  FIG. 2 ; 
         FIG. 5  is a side elevation view of the forming drum and a calendering station that form part of the apparatus according to the present invention; 
         FIG. 6  is a detailed perspective view of the calendering station shown in  FIG. 5 , depicting the vacuum roll and calender roll thereof; 
         FIG. 7  is a elevation view of the that portion of the calendering station calender roll circled in  FIG. 6 ; 
         FIG. 8  is a sectional view taken along line  8 - 8  in  FIG. 6 ; 
         FIG. 9  is a detailed perspective view of that portion of the calendering station vacuum roll circled in  FIG. 6 ; 
         FIG. 10  is a perspective view of a formed fibrous article according to the invention after passing through the calendering station; 
         FIG. 11  is a side elevation view of a pin calendering station that forms part of the apparatus according to the present invention; 
         FIG. 12  is a detailed perspective view of the pin calendering station shown in  FIG. 11 , depicting the vacuum roll and pin calender roll thereof; 
         FIG. 13  is a partially exploded perspective view of the pin calendering station pin calender roll; 
         FIG. 14  is a detailed plan view of that portion of the pin calender roll circled in  FIG. 13 ; 
         FIG. 15  is a sectional view taken along line  15 - 15  in  FIG. 14 ; 
         FIG. 16  is detailed perspective view of that portion of the pin calender roll circled in  FIG. 13 ; 
         FIG. 17  is a sectional view taken along line  17 - 17  in  FIG. 11 ; 
         FIG. 18  is a sectional view taken along line  18 - 18  in  FIG. 12 ; 
         FIG. 19  is a side elevation view of a transfer wheel that forms part of the apparatus according to the present invention; 
         FIG. 20  is a perspective view of the transfer wheel shown in  FIG. 19 ; 
         FIG. 21  is a top plan view of the formed fibrous article after passing through the pin calendering station; 
         FIG. 22  is a detailed perspective view of that portion of the formed fibrous article circled in  FIG. 21 ; 
         FIG. 23  is a perspective view of an absorbent article according to the present invention with the cover layer and transfer layer thereof partially broken away; 
         FIG. 24  is a sectional view taken along line  24 - 24  in  FIG. 23 ; and 
         FIGS. 25-26  are perspective views of alternate embodiments of absorbent articles according to the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIGS. 1-9  and  11 - 20 , there is illustrated a preferred apparatus  10  for making a formed fibrous article  12  according to the method of the present invention. 
     As shown in  FIG. 1 , the apparatus  10  according to the present invention generally includes a forming drum  14 , a calendering station  16 , a pin calendering station  18 , and a transfer wheel  20 . Certain details of the apparatus  10 , such as electrical lines, have been omitted from the figures to simplify the same. However, these features and other basic elements of the apparatus will be clear to those of skill in the art. 
     The formed fibrous article  12 , which is depicted during various stages of the method according to the present invention in  FIGS. 3 ,  5 - 6 ,  8 ,  10 ,  12  and  18 - 22 , preferably is formed from cellulosic fibers, and in a preferred embodiment of the invention, includes a mixture of cellulosic fibers and superabsorbent polymer. Cellulosic fibers that can be used in the formed fibrous article  12  are well known in the art and include wood pulp, cotton, flax and peat moss. Wood pulp is preferred. Both softwood and hardwood species are useful. Softwood pulps are preferred. 
     The fibrous article  12  may also contain any superabsorbent polymer (SAP), which are well known in the art. For the purposes of the present invention, the term “superabsorbent polymer” (or “SAP”) refers to materials, which are capable of absorbing and retaining at least about 10 times their weight in body fluids under a 0.5 psi pressure. The superabsorbent polymer particles of the invention may be inorganic or organic crosslinked hydrophilic polymers, such as polyvinyl alcohols, polyethylene oxides, crosslinked starches, guar gum, xanthan gum, and the like. The particles may be in the form of a powder, grains, granules, or fibers. Preferred superabsorbent polymer particles for use in the present invention are crosslinked polyacrylates, such as the product offered by Sumitomo Seika Chemicals Co., Ltd. of Osaka, Japan, under the designation of SA70N and products offered by Stockhausen Inc. 
     The pulp used to form the fibrous article  12  is preferably a bleached softwood pulp, produced by a Kraft process. As shown in  FIG. 1 , the pulp is provided by the manufacturer as a pulp board  22  in rolled form, the roll identified by the reference numeral  24 . The pulp board  22  is conveyed from the roll  24  to a device  26  for grinding the pulp board  22  into fibrous pulp  28 . The fibrous pulp  28  is released from the grinding device  26  into a chamber  30  for holding the fibrous pulp  28 . The apparatus  10  may further optionally include a device  32  for introducing superabsorbent polymer into the chamber  30  to thereby form a fibrous pulp and superabsorbent mixture. Any conventional device suitable for this purpose, and known to those of skill in the art, may be used for introducing the superabsorbent into the chamber  30 . 
     As best seen in  FIG. 3 , the chamber  30  has a partially open bottom portion  34  that communicates with the forming drum  14 . As seen in  FIG. 1 , the forming drum  14  includes a hollow cylinder  15  that is structured and arranged to rotate about a fixed axis  17 . Any conventional means to rotate the cylinder  15 , well known to those of skill in the art, may be used to rotate the cylinder  15 . As shown in  FIGS. 1-4 , the cylinder  15  has a plurality of molds  36  mounted thereto. As the cylinder  15  rotates, each of the molds  36  are sequentially arranged in communication with the open portion  34  of the chamber  30  to thereby receive fibrous pulp  28  from the chamber  30 . In  FIG. 1 , the cylinder  15  rotates in a counterclockwise manner during operation of the apparatus  10 . 
     As shown in  FIGS. 1 and 3 , the forming drum  14  further includes a vacuum chamber  38  arranged within the interior of the cylinder  15 . The vacuum chamber  38  is arranged in a fixed location relative to the rotating cylinder  15  and is operably coupled to a vacuum source (not shown). As best seen in  FIG. 4 , the mold  36  includes a porous screen  40  structure in the shape of the formed fibrous article  12  to be formed in the mold  36 . As the mold  36  passes over the vacuum chamber  38  of the forming drum  14  the vacuum functions to draw the fibrous pulp  28  from the chamber  30  into the mold  36  by drawing air through the porous screen  40  of the mold  36 . 
     As shown in detail in  FIG. 4 , the mold  36  includes a nonporous mounting plate portion  42  that surrounds the porous screen  40  portion of the mold  36 . The mounting plate portion  42  of the mold  36  is mounted to the periphery  44  of the cylinder  15 , thereby enabling each of the molds  36  to rotate with the rotating cylinder  15 . 
     After the mold  36  is rotated under the partially open bottom portion  34  of the chamber  30 , the mold  36  is further rotated by the rotating cylinder  15 , and as described in further detail below, the fibrous article  12  is then transferred to the calendering station  16 . 
     After formation in the mold  36 , the formed fibrous article  12  preferably has a basis weight in the range of between about 200 gsm (g/m 2 ) to about 400 gsm, a thickness in the range of about 5 mm to about 20 mm, and a density in the range of about 0.01 g/cc to about 0.03 g/cc. 
     As shown in FIGS.  1  and  5 - 9  the calendering station  16  generally includes a vacuum roll  42  and an opposed calender roll  44 . As best seen in  FIG. 6 , the vacuum roll  42  is formed from a rotatable cylinder  46  that is rotatable about a fixed axis  48 . The calender roll  44  is rotateable about a fixed axis  49 . Any conventional means to rotate the cylinder  46 , and calender roll  44 , well known to those of skill in the art, may be used to rotate cylinder  46  and calender roll  44 . The cylinder  46  rotates in a clockwise manner during operation of the apparatus  10 , and the calender roll  44  rotates in a counterclockwise manner, as show in  FIG. 1 . As best seen in  FIGS. 6 ,  8  and  9 , the cylinder  46  includes a plurality of holes  50  that extend from the outer surface  52  of the cylinder  46  to the inner surface  54  of the cylinder  46 . 
     As shown in detail in  FIG. 7 , the surface  47  of the calender roll  44  includes a recess  53 . The recess  53  may take any number of different shapes including generally oval, elliptical, circular or the like. In one preferred embodiment of the invention, as shown in  FIG. 7 , the recess generally has an oval shape. Preferably, the recess  53  extends over a surface area in range of about 500 mm 2  to about 5000 mm 2 . The recess  53  preferably has a depth in the range of about 2 mm to about 25 mm as measured from the surface  47  of the roll  44  located outside the recess  53 . The recess  53  is preferably arranged such that it is longer in the machine direction (md) than in the transverse direction (td). Preferably, the recess  53  has a maximum length, as measured in the machine direction, in the range of about 20 mm to about 120 mm and a maximum width, as measured in the transverse direction, in the range of about 5 mm to about 60 mm. 
     As shown in  FIGS. 5 ,  6  and  8 , the vacuum roll  42  further includes a vacuum chamber  56  arranged within the interior of the cylinder  46 . The vacuum chamber  56  is arranged in a fixed location relative to the rotating cylinder  46  and is operably coupled to a vacuum source  57  ( FIG. 1 ). The vacuum chamber  56  is arranged in flow communication with the plurality of holes  50  that extend through the cylinder  46  and thereby draws air through said holes  50 . 
     As shown in  FIG. 5 , the vacuum chamber  56  is arranged such that its leading edge  58  is substantially aligned with a trailing edge  60  of the vacuum chamber  38  located within cylinder  15  of the forming drum  14 . This arrangement of the vacuum chamber  56  relative to location of the vacuum chamber  38  effectuates a transfer of the formed fibrous article  12  from within the mold  36  on the forming drum  14  to the vacuum roll  42 . 
     Once the formed fibrous article  12  has been transferred to the cylinder  46  of the vacuum roll  42  the cylinder  46  rotates the fibrous  12  article until the article  12  passes through the nip  62  formed between the vacuum roll  42  and the calender roll  44 . The nip  62  preferably uniformly compresses the fibrous article  12  outside of the area defined by recess  53 . The compression of the fibrous article  12  results in a reduction in thickness of the article  12  and a corresponding increase in density in that portion of the fibrous article  12  located outside of the area of the recess  53 . In a preferred embodiment of the invention the nip  62  has a distance “d” (i.e. the distance between the surfaces of the opposed rolls) of about 0.9 mm. The distance “d” is indentified by the reference symbol “d” in  FIG. 8 . 
     As shown in  FIG. 10 , after passing through the nip  62  the fibrous article  12  generally includes two areas  59  and  61 . The first area  59 , corresponds to that portion of the article  12  that has been compressed by the rolls  42  and  44  outside of the area of the recess  53 . Area  59  preferably extends over a surface area of between about 7000 mm 2  and 14000 mm 2 , has a thickness in the range of about 4 mm to about 12 mm, and a density in the range of about 0.02 g/cc to about 0.1 g/cc. Area  61  of the article  12  is that portion of the article  12  corresponding in location to the recess  53 . Area  61  preferably extends over a surface area of between about 1000 mm 2  and 7000 mm 2 , has a thickness in the range of about 10 mm to about 20 mm, and a density in the range of about 0.01 g/cc to about 0.04 g/cc. 
     It is noted that the fibrous article  12 , after passing through the nip  62 , has a three dimensional profile. Specifically, area  59  of the fibrous article defines a substantially planar portion of the fibrous article  12  and area  61  extends upwardly from the substantially planar portion thereby defining an upwardly extending hump or raised portion. In one preferred embodiment of the invention, as shown in  FIG. 10 , area  61  is symmetrically arranged with respect to longitudinally extending central axis  13  of the fibrous article and the transversely extending central axis  19  of the fibrous article  12   
     It is noted that the fibrous article  12  has a three dimensional profile yet has a constant basis weight throughout its entire structure. Specifically, planar portion  59  and the raised portion  61  are both formed from a common material composition having a constant basis weight, yet differ in thickness and density. It is also noted that the entire fibrous article  12  is formed from a single material layer. 
     After the article  12  passes through the nip  62  the article  12  is further rotated in a clockwise direction by the cylinder  46  of the vacuum roll  43 , and as will be described in further detail below, transferred to the pin calendering station  18 . 
     As shown in FIGS.  1  and  11 - 18  the pin calendering station  18  generally includes a vacuum roll  64  and an opposed pin calender roll  65 . As best seen in  FIG. 12 , the vacuum roll  64  is formed from a rotatable cylinder  66  that is rotatable about a fixed axis  68 . Any conventional means to rotate the cylinder  66 , well known to those of skill in the art, may be used to rotate the cylinder  66 . The cylinder  66  rotates in a counterclockwise direction during operation of the apparatus  10 . As shown in  FIG. 12 , the cylinder  66  includes a plurality of holes  70  that extend from the outer surface  72  of the cylinder  66  to the inner surface  74  of the cylinder  66 . In a preferred embodiment of the invention each of the plurality of holes  70  has a diameter of about 1.5 mm and is spaced from an adjacent hole by a distance of about 4 mm (center to center). 
     As shown in  FIGS. 12 and 13  the pin calender roll  65  is structured and arranged to rotate about a fixed axis  67 . Any conventional means to rotate the pin calender roll, well known to those of skill in the art, may be used to rotate the roll  65 . As shown in  FIGS. 13 and 14  the pin calender roll  65  has a roll surface  80  including a first area  69  having plurality of individual pins  78  that extend outwardly from a surface  80  of the roll  65 . As shown in  FIG. 13 , the first area  69  extends down a central portion of the roll surface  80 . In a preferred embodiment of the invention, the first area  69  is structured and arranged to emboss a central region of the fibrous article  12 . Alternatively, the first area  69  may be arranged to emboss substantially the entire fibrous article  12 . 
     As best seen in  FIG. 14 , the surface  80  of the roll  65  is further provided with a first recess  77  and a second recess  79 . Each of the first recess  77  and second recess  79  are structured and arranged to correspond in location to area  61  of the fibrous article  12  when the article  12  passes through the nip  92  defined between the vacuum roll  64  and the pin calender roll  65 . Preferably each recess  77  and  79  extends over a surface area of between about 260 mm 2  and 1100 mm 2  and has a depth of between about 2 mm and 25 mm. 
     As shown in  FIG. 14 , in a preferred embodiment of the invention, each recess  77  and  79  is generally arcuate in shape and generally extends in a machine direction. Each recess  77  and  79  is preferably positioned on the roll  65  so that it is symmetrically arranged with respect to the other recess about the longitudinally extending central axis  13  of the fibrous article and the transversely extending central axis  19  of the fibrous article  12 , as the article  12  passes through the through the nip  92  defined between the vacuum roll  64  and the pin calender roll  65 . 
     Recess  77  is separated from recess  79  by a land area  81  that includes a plurality of pins  78 . Preferably the land area  81  has a surface area of between about 250 mm 2  and 1000 mm 2 . The land area  81  is connected to the first area  67  by a first smooth roll surface segment  83  and second smooth roll surface segment  85 , each of the segments  83  and  85  being preferably free of pins  78 . 
     In preferred embodiments of the invention each of the pins  78  are spaced from an adjacent pin by a distance of about 4 mm (center to center), have height of about 1.5 mm and have an effective contact area of from about 0.8 mm 2  to about 1.2 mm 2 . 
     As shown in  FIGS. 17 and 18 , each of the pins  78  are arranged such that they do not overlap with any of the plurality of holes  70  in the cylinder  66  of the vacuum roll  64 . This arrangement of the pins  78  relative to the holes  70  insures that no pulp is forced into any of the plurality of holes  70 , thereby improving the efficiency of pulp use and the efficiency of the process as a whole. 
     As shown in  FIGS. 11-12  and  17 - 18 , the vacuum roll  64  further includes a vacuum chamber  86  arranged within the interior of the cylinder  66 . The vacuum chamber  86  is arranged in a fixed location relative to the rotating cylinder  66  and is operably coupled to the vacuum source  57  ( FIG. 1 ). The vacuum chamber  86  is arranged in flow communication with the plurality of holes  70  that extend through the cylinder  66  and thereby draws air through said holes  70 . 
     As shown in  FIG. 11 , the vacuum chamber  86  is arranged such that its leading edge  88  is substantially aligned with a trailing edge  90  of the vacuum chamber  56  located within the cylinder  46  of the vacuum roll  42 . This arrangement of the vacuum chamber  86  relative to the location of the vacuum chamber  56  effectuates a transfer of the formed fibrous article  12  from the vacuum roll  42  to the vacuum roll  64 . 
     Once the formed fibrous article  12  has been transferred to the cylinder  66  of the vacuum roll  64 , the cylinder  66  rotates the formed fibrous article  12  until the article  12  passes through the nip  92  formed by the vacuum roll  64  and the pin calender roll  65 . 
     In a preferred embodiment of the invention the nip  92  has a distance (i.e. the distance between the surfaces of the opposed rolls) of about 0.8 mm. Also in a preferred embodiment of the invention the pin calender roll  65  is heated to a temperature of between about 176° F. to about 212° F. by means of any suitable conventional heating means. It has been found that heating the pin calender roll  65  in this manner helps prevent the formed fibrous article  12  from adhering to the surface of the pin calender roll  65 . 
     After the article  12  passes through the nip  92  the article  12  is further rotated in a counter clockwise direction by the cylinder  66  of the vacuum roll  64  as shown and, as will be described in further detail below, transferred to the transfer wheel  20 . 
     As shown in  FIG. 19  the transfer wheel  20  comprises a vacuum roll  94  that is formed from a rotatable cylinder  96  that is rotatable about a fixed axis  98 . Any conventional means to rotate the cylinder  96 , well known to those of skill in the art, may be used to rotate the cylinder  96 . The cylinder  96  rotates in a counterclockwise manner during operation of the apparatus  10 , as show in  FIG. 1 . As shown in  FIG. 20 , the cylinder  96  includes a plurality of holes  100  that extend from the outer surface  102  of the cylinder  96  to the inner surface  104  of the cylinder  96 . 
     As shown in  FIGS. 19 and 20 , the vacuum roll  94  further includes a vacuum chamber  106  arranged within the interior of the cylinder  96 . The vacuum chamber  106  is arranged in a fixed location relative to the rotating cylinder  96  and is operably coupled to the vacuum source  57  ( FIG. 1 ). The vacuum chamber  106  is arranged in flow communication with the plurality of holes  100  that extend through the cylinder  96  and thereby draw air through said holes  100 . 
     The transfer wheel  20  further includes a porous conveyor belt  97  that extends around the cylinder  96  and travels with the cylinder  96 , i.e. in a clockwise direction shown in  FIG. 20 . 
     As shown in  FIG. 19 , the vacuum chamber  106  is arranged such that its leading edge  108  is substantially aligned with a trailing edge  110  of the vacuum chamber  86  located within the cylinder  66  of the vacuum roll  64 . This arrangement of the vacuum chamber  106  relative to the location of the vacuum chamber  86  effectuates a transfer of the formed fibrous article  12  from the vacuum roll  64  to the vacuum roll  94 . Specifically, formed fibrous article  12  is transferred to the conveyor belt  97  and held in place by the vacuum chamber  106  that functions to draw air through the porous conveyer belt  97  via the holes  100  in the cylinder  96 . 
     Once the fibrous article  12  is rotated past vacuum chamber  106 , the porous conveyer belt  97  functions to further convey the formed fibrous article  12  in a machine direction. The formed fibrous article  12  may be conveyed in a machine direction for incorporation into a final product structure such as a sanitary napkin, panty liner, incontinence article, diaper or the like. 
     Referring to  FIGS. 21 and 22 , the completed fibrous article  12  generally includes an area  101  that has not been pin embossed, a first arcuate raised area  103 , a second arcuate raised area  105 , a pin embossed region  107  located between the raised area  103  and raised area  105 , and a centrally extending pin embossed area  109  extending along the longitudinally extending central axis  13  of the article  12 . Each of the pin embossed regions  107  and  109  include a plurality of depressions  111  corresponding in location to the pins  78 . Areas  101  and  109  cooperate to define a substantially planar portion of the fibrous article  12  and raised areas  103  and  105  extend upwardly relative to the planar portion of the fibrous article  12 . 
     After passing through the nip  92  area  101  preferably has a thickness in the range of about 0.8 mm to about 3.5 mm, a density in the range of about 0.06 g/cc to about 0.5 g/cc, and extends over a surface area of from about 6400 mm 2  and 9400 mm 2 . 
     After passing through the nip  92  each of area  103  and  105  preferably has a thickness in the range of about 2 mm to about 10 mm and a density in the range of about 0.01 g/cc to about 0.1 g/cc. Each area  103  and  105  preferably extends over a surface area of from about 260 mm 2  and 1100 mm 2 . 
     After passing through the nip  92  area  107  preferably has a thickness in the range of about 0.2 mm to about 1 mm, a density in the range of about 0.1 g/cc to about 0.9 g/cc in those areas  111  embossed by the pins  78  and a thickness in the range of about 0.8 mm to about 3.5 mm and a density in the range of about 0.06 g/cc to about 0.5 g/cc in those areas outside of areas  111 . Area  107  preferably extends over a surface area of from about 250 mm 2  and 1000 mm 2 . 
     After passing through the nip  92  area  109  preferably has a thickness in the range of about 0.2 mm to about 1.0 mm and a density in the range of about 0.1 g/cc to about 0.9 g/cc in those areas  111  embossed by the pins  78  and a thickness in the range of about 0.8 mm to about 3.5 mm and a density in the range of about 0.06 g/cc to about 0.5 g/cc in those areas outside of areas  111 . Area  109  preferably extends over a surface area of from about 2400 mm 2  and 7600 mm 2 . 
     It is noted that although the different areas of the fibrous article  12  differ in density and thickness the fibrous article  12  has a uniform basis weight throughout its entire structure. It is further noted that although fibrous article  12  according to the present invention possesses at least one raised area, i.e. the article  12  possesses a three dimensional profile, the article  12  has a uniform basis weight. Preferred embodiments of the present invention also present the above characteristics while being formed from a uniform material composition. In addition, in preferred embodiments of the present invention, the fibrous article  12  is formed from a single material layer. 
     It is noted that the formed fibrous article  12  is formed and pin-calendered without the use of any “carrier layer”. In addition, is noted that the fibrous article is transferred from the forming drum  14  to the calendering station  16  then to the pin calendering station  18  without the use of any “carrier layer”. “Carrier layer” as used herein means any material layer used to support the fibrous article, such as a conveyer belt or an adjacent material layer such a rolled nonwoven layer or the like. 
     In connection with the various vacuum chambers disclosed herein any suitable vacuum source may be employed. In a preferred embodiment of the invention the vacuum source is an air blower having an air flow of about 2,200 cubic meters per hour. 
     Reference is made to  FIGS. 23-24  which depict a disposable absorbent article  200  in accordance with the present invention. Although disposable absorbent articles according to the present invention will be described herein with reference to a sanitary napkin  200 , other disposable absorbent articles such as panty liners, adult incontinence articles, and diapers are considered within the scope of the present invention. As shown in  FIG. 24 , the sanitary napkin  200  includes a liquid permeable cover layer  210 , an optional transfer layer  212 , an absorbent core  214  and a liquid impermeable barrier layer  216 . The absorbent core  214  layer is formed from a formed fibrous article  12  of the type described above. 
     As shown in  FIG. 23 , the absorbent article  200  includes a raised area  213  that extends upwardly from the remaining body facing planar portion  215  of the napkin  200 . Specifically the raised area  213  extends upwardly from a top surface  217  of the planar portion  215 . Preferably, the raised area  213  extends upwardly a distance of about 2 mm to about 10 mm as measured from the top surface  217  of the planar portion  215  and extends over a surface area of between about 1000 mm 2  and 7000 mm 2 . Preferably, the planar portion  215  extends over an area of between about 7000 mm 2  and 14000 mm 2 . 
     Main Body—Cover Layer 
     The cover layer  210  may be a relatively low density, bulky, high-loft non-woven web material. The cover layer  210  may be composed of only one type of fiber, such as polyester or polypropylene or it may include a mixture of more than one fiber. The cover may be composed of bi-component or conjugate fibers having a low melting point component and a high melting point component. The fibers may be selected from a variety of natural and synthetic materials such as nylon, polyester, rayon (in combination with other fibers), cotton, acrylic fiber and the like and combinations thereof. Preferably, the cover layer  210  has a basis weight in the range of about 10 gsm to about 75 gsm. 
     Bi-component fibers may be made up of a polyester layer and a polyethylene sheath. The use of appropriate bi-component materials results in a fusible non-woven fabric. Examples of such fusible fabrics are described in U.S. Pat. No. 4,555,430 issued Nov. 26, 1985 to Chicopee. Using a fusible fabric increases the ease with which the cover layer may be mounted to the absorbent layer(s) of the article and/or to the barrier layer  216 . 
     The cover layer  210  preferably has a relatively high degree of wettability, although the individual fibers comprising the cover may not be particularly hydrophilic. The cover material should also contain a great number of relatively large pores. This is because the cover layer  210  is intended to take-up body fluid rapidly and transports it away from the body and the point of deposition. Therefore, the cover layer contributes little to the time taken for the napkin  200  to absorb a given quantity of liquid (penetration time). 
     Advantageously, the fibers that make up the cover layer  210  should not lose there physical properties when they are wetted, in other words they should not collapse or lose their resiliency when subjected to water or body fluid. The cover layer  210  may be treated to allow fluid to pass through it readily. The cover layer  210  also functions to transfer the fluid quickly to the underlying layers of the absorbent article. Thus, the cover layer  210  is advantageously wettable, hydrophilic and porous. When composed of synthetic hydrophobic fibers such as polyester or bi-component fibers, the cover layer  210  may be treated with a surfactant to impart the desired degree of wettability. 
     In one preferred embodiment of the invention the cover layer  210  is made from a 27 gsm hot through air (HTA) bonded nonwoven material constructed from 100% bico fibers (PE/PET), commercially available from Shalag Industries A.C.S. Ltd., Kibbutz Shamir, Upper Galilee, Israel, under the commercial code STA4ETW27. 
     Alternatively, the cover layer  210  can also be made of a polymer film having large pores. Because of such high porosity, the film accomplishes the function of quickly transferring body fluid to the underlying layers of the absorbent article. A suitable cover material of this type is commercially found on the Stayfree Dry Max Ultrathin product distributed by McNeil-PPC, Inc. 
     The cover layer  210  may be embossed to the underlying absorbent layers in order to aid in promoting hydrophilicity by fusing the cover to the adjacent underlying layer. Such fusion may be effected locally, at a plurality of sites or over the entire contact surface of cover layer  210 . Alternatively, the cover layer  210  may be attached to the other layers of the article by other means such as by adhesion. 
     Main Body—Transfer Layer 
     Adjacent to the cover layer  210  on its inner side and bonded to the cover layer  210  is the optional transfer layer  212 . The transfer layer  212  provides means for receiving body fluid from the cover layer  210  and holding it until the underlying absorbent core  214  has an opportunity to absorb the fluid, and therefore acts as a fluid transfer or acquisition layer. The transfer layer  212  is, preferably, more dense than and has a larger proportion of smaller pores than the cover layer  210 . These attributes allow the transfer layer  212  to contain body fluid and hold it away from the outer side of the cover layer  210 , thereby preventing the fluid from rewetting the cover layer  210  and its surface. However, the transfer layer is, preferably, not so dense as to prevent the passage of the fluid through the layer  212  into the underlying absorbent core  214 . 
     The transfer layer  212  may be composed of fibrous materials, such as wood pulp, polyester, rayon, flexible foam, or the like, or combinations thereof. The transfer layer  212  may also comprise thermoplastic fibers for the purpose of stabilizing the layer and maintaining its structural integrity. The transfer layer  212  may be treated with surfactant on one or both sides in order to increase its wettability, although generally the transfer layer  212  is relatively hydrophilic and may not require treatment. The transfer layer  212  is preferably bonded or adhered on both sides to the adjacent layers, i.e. the cover layer  210  and the underlying absorbent core  214 . 
     Examples of suitable materials for the transfer layer  212  are through air bonded pulp sold by Buckeye Technologies of Memphis, Tenn., under the designation VIZORB 3008, which has a basis weight of 110 gsm, VIZORB 3042, which has a basis weight of 100 gsm, and VIZORB 3010, which has a basis weight of 90 gsm. 
     Main Body—Absorbent Core 
     Referring to  FIG. 18 , and as discussed above, the absorbent article  200  according to the present invention includes an absorbent core  214 . The absorbent core  214  consists of a formed fibrous article  12  of the type described herein above. 
     In one preferred embodiment of the invention, the absorbent core  214  is a blend or mixture of cellulosic fibers and superabsorbent disposed therein. Cellulosic fibers that can be used in the absorbent core  214  are well known in the art and include wood pulp, cotton, flax and peat moss. Wood pulp is preferred. 
     The absorbent core  214  can contain any superabsorbent polymer (SAP), which are well known in the art. For the purposes of the present invention, the term “superabsorbent polymer” (or “SAP”) refers to materials, which are capable of absorbing and retaining at least about 10 times their weight in body fluids under a 0.5 psi pressure. The superabsorbent polymer particles of the invention may be inorganic or organic crosslinked hydrophilic polymers, such as polyvinyl alcohols, polyethylene oxides, crosslinked starches, guar gum, xanthan gum, and the like. The particles may be in the form of a powder, grains, granules, or fibers. Preferred superabsorbent polymer particles for use in the present invention are crosslinked polyacrylates, such as the product offered by Sumitomo Seika Chemicals Co., Ltd. of Osaka, Japan, under the designation of SA70N and products offered by Stockhausen Inc. 
     The absorbent core  214  preferably has a total basis weight in the range of about 200 gsm to about 400 gsm. In preferred embodiments of the present invention the absorbent core  214  includes about 50%-100% pulp by weight and about 0% to about 50% superabsorbent by weight. 
     As described above in the description of the method of making the fibrous article  12  set forth above, and in reference to  FIGS. 21 and 22 , the absorbent core  214  generally includes an area  101  that has not been pin embossed, a first arcuate raised area  103 , a second arcuate raised area  105 , a pin embossed region  107  located between the raised area  103  and raised area  105 , and a centrally extending pin embossed area  109 . Referring to  FIG. 24 , it is noted that the region  107  located between the raised areas  103  and  105  is recessed related to the raised areas. That is, raised areas  103  and  105  have a greater thickness than region  107 . 
     As shown in  FIG. 24 , the first arcuate raised area  103  and the second arcuate raised area  105  of the absorbent core  214  correspond in location, and help define, the raised area  213  of the napkin  200 . However, it is noted that the final shape of the raised area  213  of the napkin  200  is provided by a conventional embossing step (not shown in the figures) and thus the shape of the raised area  213  is not dictated solely by the shape of the first arcuate raised area  103  and the second arcuate raised area  105 . The raised area  213  of the napkin  200  may be formed to have any number of different shapes. For example, two alternate embodiments of the napkin  200   a  and  200   b  are depicted in  FIGS. 25 and 26 . As shown, napkins  200   a  and  200   b  include raised areas  213  having different shapes than the napkin  200  shown in  FIGS. 23 and 24 . Other shapes are also possible. In addition, although the napkin  200  is depicted as having only a single raised area  213  is possible that the napkin could be provided with a plurality of such raised areas  213 . 
     All of the articles shown in  FIGS. 23-26  use absorbent cores having raised areas  103  and  105  as shown in  FIG. 21 , and the final shape of the raised area  213  has been modified merely by using a correspondingly shaped conventional embossing roll to emboss the napkin  200  after the various layers of the napkin  200  have been adhered to one another. 
     Referring to  FIG. 24 , it is noted that the cover layer extends over the first arcuate raised area  103 , the second arcuate raised area  105 , as well as the region  107  located between the raised area  103  and raised area  105 . In this manner, the cover layer  210  generally includes a first portion  221  which is located in body facing planar portion  215  of the napkin  200  and is arranged in abutting surface to surface contact with the transfer layer  212  (or the absorbent core  214  if the transfer layer  212  is omitted), a pair of second regions  223  that are arranged in corresponding location to the arcuate raised areas  103  and  105  of the absorbent core  214 , and a third region  225  that is located between the arcuate raised areas  103  and  105  and is arranged in spaced relationship to the absorbent core  214 . 
     In one specific example of the invention, the absorbent core  214  consists of a 305 gsm fluff pulp and superabsorbent mixture, the mixture including about 89% fluff pulp by weight, commercially available as Golden Isles Fluff Pulp 420#HD 7% Moisture, from GP Cellulose, Brunswick, Ga., USA, and 11% superabsorbent polymer by weight, commercially available as Aqua Keep SA70N from Sumitomo Seika Chemicals Co., Ltd., Osaka, Japan. 
     Main Body—Barrier Layer 
     Underlying the absorbent core  214  is a barrier layer  216  comprising liquid-impervious film material so as to prevent liquid that is entrapped in the absorbent core  214  from egressing the sanitary napkin  200  and staining the wearer&#39;s undergarment. The barrier layer  216  is preferably made of polymeric film, although it may be made of liquid impervious, air-permeable material such as repellent-treated non-woven or micropore films or foams. 
     The barrier layer may be breathable, i.e., permits vapor to transpire. Known materials for this purpose include nonwoven materials and microporous films in which microporosity is created by, inter alia, stretching an oriented film. Single or multiple layers of permeable films, fabrics, melt-blown materials, and combinations thereof that provide a tortuous path, and/or whose surface characteristics provide a liquid surface repellent to the penetration of liquids may also be used to provide a breathable backsheet. The cover layer  210  and the barrier layer  216  are joined along their marginal portions so as to form an enclosure or flange seal that maintains the absorbent core  214  captive. The joint may be made by means of adhesives, heat-bonding, ultrasonic bonding, radio frequency sealing, mechanical crimping, and the like and combinations thereof. 
     In one specific example of the invention, the barrier layer consists of a liquid impermeable 24 gsm polyethylene film commercially available from Clopay do Brasil, Sau Paulo, SP, Brazil. 
     Positioning adhesive may be applied to a garment facing side of the barrier layer  216  for securing the napkin  200  to the garment during use. The positioning adhesive may be covered with removable release paper so that the positioning adhesive is covered by the removable release paper prior to use. 
     Absorbent articles of this invention may or may not include wings, flaps or tabs for securing the absorbent article to an undergarment. Wings, also called, among other things, flaps or tabs, and their use in sanitary protection articles is described in U.S. Pat. No. 4,687,478 to Van Tilburg; U.S. Pat. No. 4,589,876 also to Van Tilburg, U.S. Pat. No. 4,900,320 to McCoy, and U.S. Pat. No. 4,608,047 to Mattingly. 
     The sanitary napkin  200  of the present invention may be applied to the crotch by placing the garment-facing surface against the inside surface of the crotch of the garment. Various methods of attaching absorbent articles may be used. For example, chemical means, e.g., adhesive, and mechanical attachment means, e.g., clips, laces, ties, and interlocking devices, e.g., snaps, buttons, VELCRO (Velcro USA, Inc., Manchester, N.H.), zipper, and the like are examples of the various options available to the artisan. 
     Adhesive may include pressure sensitive adhesive that is applied as strips, swirls, or waves, and the like. As used herein, the term pressure-sensitive adhesive refers to any releasable adhesive or releasable tenacious means. Suitable adhesive compositions, include, for example, water-based pressure-sensitive adhesives such as acrylate adhesives. Alternatively, the adhesive composition may include adhesives based on the following: emulsion or solvent-borne adhesives of natural or synthetic polyisoprene, styrenebutadiene, or polyacrylate, vinyl acetate copolymer or combinations thereof; hot melt adhesives based on suitable block copoylmers—suitable block copolymers for use in the invention include linear or radial co-polymer structures having the formula (A−B)x wherein block A is a polyvinylarene block, block B is a poly(monoalkenyl) block, x denotes the number of polymeric arms, and wherein x is an integer greater than or equal to one. Suitable block A polyvinylarenes include, but are not limited to Polystyrene, Polyalpha-methylstyrene, Polyvinyltoluene, and combinations thereof. Suitable Block B poly(monoalkenyl) blocks include, but are not limited to conjugated diene elastomers such as for example polybutadiene or polyisoprene or hydrogenated elastomers such as ethylene butylene or ethylene propylene or polyisobutylene, or combinations thereof. Commercial examples of these types of block copolymers include Kraton™ elastomers from Shell Chemical Company, Vector™ elastomers from Dexco, Solprene™ from Enichem Elastomers and Stereon™ from Firestone Tire &amp; Rubber Co.; hot melt adhesive based on olefin polymers and copolymers where in the olefin polymer is a terpolymer of ethylene and a co-monomers, such as vinyl acetate, acrylic acid, methacrylic acid, ethyl acrylate, methyl acrylate, n-butyl acrylate vinyl silane or maleic anhydride. Commercial examples of these types of polymers include Ateva (polymers from AT plastics), Nucrel (polymers from DuPont), Escor (from Exxon Chemical). 
     Any or all of the cover layer  210 , transfer layer  212 , absorbent core  214 , barrier layer  216 , and adhesive layers may be colored. Such coloring includes, but is not limited to, white, black, red, yellow, blue, orange, green, violet, and mixtures thereof. Color may be imparted according to the present invention through dying, pigmentation, and printing. Colorants used according the present invention include dyes and inorganic and organic pigments. The dyes include, but are not limited to, anthraquinone dyes (Solvent Red 111, Disperse Violet 1, Solvent Blue 56, and Solvent Green 3), Xanthene dyes (Solvent Green 4, Acid Red 52, Basic Red 1, and Solvent Orange 63), azine dyes (Jet black), and the like. Inorganic pigments include, but are not limited to, titanium dioxide (white), carbon black (black), iron oxides (red, yellow, and brown), chromium oxide (green), ferric ammonium ferrocyanide (blue), and the like. 
     Organic pigments include, but are not limited to diarylide yellow AAOA (Pigment Yellow 12), diarylide yellow AAOT (Pigment Yellow 14), phthalocyanine blue (Pigment Blue 15), lithol red (Pigment Red 49:1), Red Lake C (Pigment Red), and the like. 
     The sanitary napkin  200  may include other known materials, layers, and additives, such as, foam, net-like materials, perfumes, medicaments or pharmaceutical agents, moisturizers, odor control agents, and the like. The sanitary napkin  200  can optionally be embossed with decorative designs. 
     The sanitary napkin  200  may be packaged as unwrapped absorbent articles within a carton, box or bag. The consumer withdraws the ready-to-use article as needed. The sanitary napkin  200  may also be individually packaged (each absorbent article encased within an overwrap). 
     Also contemplated by the present invention are asymmetrical and symmetrical absorbent articles having parallel longitudinal edges, dog bone- or peanut-shaped, as well as articles having a tapered construction for use with thong-style undergarments. 
     From the foregoing description, one skilled in the art can ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications. Embodiments set forth by way of illustration are not intended as limitations on the variations possible in practicing the present invention. 
     EXAMPLES 
     Specific inventive examples of the present invention, and comparative examples, are described below. 
     Inventive Example #1 
     An example of a sanitary napkin according to the invention was constructed as follows. The body facing cover layer was constructed from a 27 gsm hot through air (HTA) bonded nonwoven material constructed from 100% bico fibers (PE/PET), commercially available from Shalag Industries A.C.S. Ltd., Kibbutz Shamir, Upper Galilee, Israel, under the commercial code STA4ETW27. 
     A 305 gsm formed fibrous absorbent core was arranged below the cover layer and was formed by the process described herein above with reference to  FIGS. 1-21 . 
     The absorbent core had a composition of 89% by weight of pulp and 11% by weight of superabsorbent polymer. The pulp was Golden Isles Fluff Pulp 420#HD 7% Moisture, commercially available from GP Cellulose, Brunswick, Ga., USA. The superabsorbent polymer was Aqua Keep SA70N commercially available from Sumitomo Seika Chemicals Co., Ltd., Osaka, Japan. 
     As described above with reference to  FIGS. 21-22 , the absorbent core (i.e. the formed fibrous article  12 ) was formed to include an area  101  that was not been pin embossed, a first arcuate raised area  103 , a second arcuate raised area  105 , a pin embossed region  107  located between the raised area  103  and raised area  105 , and a centrally extending pin embossed area  109  extending along the longitudinally extending central axis of the article  12 , as shown in  FIG. 21 . 
     Area  101  had a thickness in the range of about 2 mm, a density of about 0.1 g/cc, and extended over a surface area of 6500 mm 2 . 
     Area  103  and  105  each had a thickness of 5 mm and a density of about 0.05 g/cc. Each area  103  and  105  extended over a surface area of 557 mm 2 . 
     Area  107  had a thickness of 0.2 mm and a density of 0.5 g/cc in those areas  111  embossed by the pins  78  and a density of 0.3 g/cc and a thickness of 1 mm in those areas outside of areas  111 . Area  107  extended over a surface area of 504 mm 2 . 
     Area  109  had a thickness of 0.2 mm and a density of 0.5 g/cc in those areas  111  embossed by the pins  78  and a thickness of 1 mm and a density of 0.3 g/cc in those areas outside of areas  111 . Area  109  extended over a surface area of 4300 mm 2 . 
     A barrier layer was arranged below the core and was formed from a 24 gsm polyethylene film commercially available from Clopay do Brasil, Sao Paulo, SP, Brazil. 
     Each of the layers of the sanitary napkin were adhered to one another using a conventional hot melt adhesive. After each of the layers were adhered to one another the sanitary napkin was passed through a conventional embossing process to form a raised area of the type shown in  FIG. 23 . Thus, the sanitary napkin included a planar portion  215  and a raised area  213  extending upwardly form the planar portion  215  as depicted in  FIG. 23 . The planar portion  215  extended over an area of 13000 mm 2  and the raised area  213  extended over an area of 2000 mm 2 . The sanitary napkin had a thickness of 2.2 mm in the planar portion  215  and a thickness of 4.7 mm in the raised area  213 . 
     Inventive Example #2 
     An example of a sanitary napkin according to the invention was constructed as follows. The body facing cover layer was constructed from a 27 gsm hot through air (HTA) bonded nonwoven material constructed from 100% bico fibers (PE/PET), commercially available from Shalag Industries A.C.S. Ltd., Kibbutz Shamir, Upper Galilee, Israel, under the commercial code STA4ETW27. 
     A 305 gsm formed fibrous absorbent core was arranged below the cover layer and was formed by the process described herein above with reference to  FIGS. 1-21 . 
     The absorbent core had a composition of 89% by weight of pulp and 11% by weight of superabsorbent polymer. The pulp was Golden Isles Fluff Pulp 420#HD 7% Moisture, commercially available from GP Cellulose, Brunswick, Ga., USA. The superabsorbent polymer was Aqua Keep SA70N commercially available from Sumitomo Seika Chemicals Co., Ltd., Osaka, Japan. 
     As described above with reference to  FIGS. 21-22 , the absorbent core (i.e. the fibrous article  12 ) was formed to include an area  101  that was not been pin embossed, a first arcuate raised area  103 , a second arcuate raised area  105 , a pin embossed region  107  located between the raised area  103  and raised area  105 , and a centrally extending pin embossed area  109  extending along the longitudinally extending central axis  13  of the article  12 , as shown in  FIG. 21 . 
     Area  101  had a thickness in the range of about 3 mm, a density of about 0.09 g/cc, and extended over a surface area of 6500 mm 2 . 
     Area  103  and  105  each had a thickness of 6 mm and a density of about 0.04 g/cc. Each area  103  and  105  extended over a surface area of 557 mm 2 . 
     Area  107  had a thickness of 0.2 mm and a density of 0.5 g/cc in those areas  111  embossed by the pins  78  and a density of 0.3 g/cc and a thickness of 1 mm in those areas outside of areas  111 . Area  107  extended over a surface area of 504 mm 2 . 
     Area  109  had a thickness of 0.2 mm and a density of 0.5 g/cc in those areas  111  embossed by the pins  78  and a thickness of 1 mm and a density of 0.3 g/cc in those areas outside of areas  111 . Area  109  extended over a surface area of 4300 mm 2 . 
     Each of the layers of the sanitary napkin were adhered to one another using a conventional hot melt adhesive. After each of the layers were adhered to one another the sanitary napkin was passed through a conventional embossing process to form a raised area of the type shown in  FIG. 23 . Thus, the sanitary napkin included a planar portion  215  and a raised area  213  extending upwardly form the planar portion  215  as depicted in  FIG. 23 . The planar portion  215  extended over an area of 13000 mm 2  and the raised area  213  extended over an area of 2000 mm 2 . The sanitary napkin had a thickness of 3.3 mm in the planar portion  215  and a thickness of 5.8 mm in the raised area  213 . 
     Comparative Example #1 
     A comparative example, representative of the prior art, was construed as follows. The body facing cover layer was constructed from a 27 gsm hot through air (HTA) bonded nonwoven material constructed from 100% bico fibers (PE/PET), commercially available from Shalag Industries A.C.S. Ltd., Kibbutz Shamir, Upper Galilee, Israel, under the commercial code STA4ETW27. 
     A 305 gsm fibrous absorbent core was arranged below the cover layer. 
     The absorbent core had a composition of 89% by weight of pulp and 11% by weight of superabsorbent polymer. The pulp was Golden Isles Fluff Pulp 420#HD 7% Moisture, commercially available from GP Cellulose, Brunswick, Ga., USA. The superabsorbent polymer was Aqua Keep SA70N commercially available from Sumitomo Seika Chemicals Co., Ltd., Osaka, Japan. The absorbent core has a uniform thickness along its length of 2.2 mm and a uniform density along its length of 0.1 g/cc. 
     Comparative Example #2 
     A comparative example, representative of the prior art, was construed as follows. The body facing cover layer was constructed from a 27 gsm hot through air (HTA) bonded nonwoven material constructed from 100% bico fibers (PE/PET), commercially available from Shalag Industries A.C.S. Ltd., Kibbutz Shamir, Upper Galilee, Israel, under the commercial code STA4ETW27. 
     A 305 gsm fibrous absorbent core was arranged below the cover layer. 
     The absorbent core had a composition of 89% by weight of pulp and 11% by weight of superabsorbent polymer. The pulp was Golden Isles Fluff Pulp 420#HD 7% Moisture, commercially available from GP Cellulose, Brunswick, Ga., USA. The superabsorbent polymer was Aqua Keep SA70N commercially available from Sumitomo Seika Chemicals Co., Ltd., Osaka, Japan. The absorbent core has a uniform thickness along its length of 3.3 mm and a uniform density along its length of 0.09 g/cc. 
     Test Procedures 
     Absorbent articles according to the present invention provide superior fluid handling characteristics. A number of test procedures are described below that highlight the fluid handling properties of absorbent articles according to the present invention. Prior to conducting any of the described test procedures described below the test product samples should be conditioned for two hours at 21+/−1° C. and 50+/−2% humidity. 
     Procedure for Measuring Fluid Penetration Time 
     Fluid Penetration Time is measured by placing a product sample to be tested under a Fluid Penetration Test orifice plate. The orifice plate consists of a 7.6 cm×25.4 cm plate of 1.3 cm thick polycarbonate with an elliptical orifice in its center. The elliptical orifice measures 3.8 cm along its major axis and 1.9 cm along its minor axis. The orifice plate is arranged such that the center of the orifice is aligned with the intersection of the longitudinal and transverse axis of the article, i.e. at the center of the article. 
     Test fluid was made of the following mixture to simulate bodily fluids: 
     49.5% of 0.9% sodium chloride solution (VWR catalog #VW 3257-7), 49.05% Glycerin (Emery 917), 1% Phenoxyethanol (Clariant Corporation Phenoxetol™) and 0.45% Sodium Chloride (Baker sodium chloride crystal # 9624-05). 
     A graduated 10 cc syringe containing 7 ml of test fluid is held over the orifice plate such that the exit of the syringe is approximately 3 inches above the orifice. The syringe is held horizontally, parallel to the surface of the test plate. The fluid is then expelled from the syringe at a rate that allows the fluid to flow in a stream vertical to the test plate into the orifice and a stop watch is started when the fluid first touches the sample to be tested. The stop watch is stopped when a portion of the surface of the sample first becomes visible above the remaining fluid within the orifice. The elapsed time on the stop watch is the Fluid Penetration Time. The average Fluid Penetration Time (FPT) is calculated from taking the average of readings from three product samples. 
     Procedure for Measuring Rewet Potential 
     The three product samples used for the Fluid Penetration Time (FPT) procedure described above are used for the Rewet Potential test described below. 
     The rewet potential is a measure of the ability of a napkin or other article to hold liquid within its structure when the napkin contains a relatively large quantity of liquid and is subjected to external mechanical pressure. The rewet potential is determined and defined by the following procedure. 
     The apparatus for the Rewet Potential test is the same as that set forth above with regard to the FPT test and further includes a quantity of 3 inch×4 (7.62 cm×10.16 cm) inch rectangles of Whatman #1 filter paper from (Whatman Inc., Clifton, N.J.) and a weighing machine or balance capable of weighing to an accuracy of +/−.0.001 g, a quantity of said Whatman paper, a standard weight of 2.22 kg (4.8 pounds) having dimensions 5.1 cm (2 inches) by 10.2 cm (4.0 inches) by approximately 5.4 cm (2.13 inches) which applies a pressure of 4.14 kPa (0.6 psi) over the 5.1 by 10.2 cm (2 inches by 4 inches) surface. 
     For purposes of the test procedure set forth herein, the same three product samples used for the fluid penetration test should be used for the rewet potential test. After the test fluid is applied within the orifice plate in the FPT test described above, and as soon as the cover layer of the napkin first appears through the top surface of the fluid, the stop watch is started and an interval of 5 minutes is measured. 
     After 5 minutes have elapsed, the orifice plate is removed and the napkin is positioned on a hard level surface with the cover layer facing upwards. 
     A fifteen (15) layer stack of the pre-weighed filter paper is placed on and centered over the wetted area and the standard 2.22 kg weight is placed on top of the filter paper. The filter paper and the weight are arranged over the absorbent article such that they are centered over the area to which the fluid was applied. The filter paper and the weight are arranged such that their longer dimensions are aligned with the longitudinal direction of the product. Immediately after placing the paper and weight on the product, the stopwatch is started and after a 3 minute interval has elapsed the standard weight and filter paper are quickly removed. The wet weight of the filter paper is measured and recorded to the nearest 0.001 grams. The rewet value is then calculated as the difference in grams between the weight of the wet 15 layers of filter paper and the dry 15 layers of filter paper. The average Rewet Potential is calculated from taking the average of readings from three product samples. 
     Procedure for Measuring the Thickness of a Sanitary Article 
     The apparatus required to measure the thickness of the sanitary napkin is a footed dial (thickness) gauge with stand, available from Ames, with a 2″ (5.08 cm) diameter foot at a pressure of 0.07 psig (4.826 hPa) and a readout accurate to 0.001″ (0.0254 mm). A digital type apparatus is preferred. If the sanitary napkin sample is individually folded and wrapped, the sample is unwrapped and carefully flattened by hand. The release paper is removed from the product sample and it is repositioned back gently across the positioning adhesive lines so as not to compress the sample, ensuring that the release paper lies flat across the sample. Flaps (if any) are not considered when taking the thickness reading. 
     The foot of the gauge is raised and the product sample is placed on the anvil such that the foot of the gauge is approximately centered on the location of interest on the product sample. When lowering the foot, care must be taken to prevent the foot dropping onto the product sample or undue force being applied. A load of 0.07 psig (4.826 hPa) is applied to the sample and the read out is allowed to stabilize for approximately 5 seconds. The thickness reading is then taken. This procedure is repeated for three product samples and the average thickness is then calculated. 
     The measured Fluid Penetration Time, Rewet Potential and Product Thickness of the Inventive Examples and Comparative Examples described above are summarized in the table set forth below. 
                                                     Thickness in   Thickness in                   Raised Area   Planar Portion   Fluid Penetra-   Rewet           (mm)   (mm)   tion Time (s)   (g)                                                        Inventive Ex-   4.7   2.2   17   0.98       ample #1       Inventive Ex-   5.8   3.3   11   0.96       ample #2       Comparative   NA   2.2   52   0.82       Example #1       Comparative   NA   3.3   25   1.43       Example #2                    
As shown above, disposable absorbent articles according to the present provide superior fluid handling characteristics.