Source: https://patents.google.com/patent/US9561139B2/en
Timestamp: 2019-07-21 15:15:44
Document Index: 238991314

Matched Legal Cases: ['art.\n14', 'art.\n37', 'Application No. 2', 'Application No. 2', 'Application No. 200780014162', 'Application No. 200780014162']

US9561139B2 - Method of making an absorbent composite and absorbent articles employing the same - Google Patents
US9561139B2
US9561139B2 US13/424,041 US201213424041A US9561139B2 US 9561139 B2 US9561139 B2 US 9561139B2 US 201213424041 A US201213424041 A US 201213424041A US 9561139 B2 US9561139 B2 US 9561139B2
US13/424,041
US20120175056A1 (en
2012-03-19 Application filed by DSG Technology Holdings Ltd filed Critical DSG Technology Holdings Ltd
2012-03-19 Priority to US13/424,041 priority patent/US9561139B2/en
2012-07-12 Publication of US20120175056A1 publication Critical patent/US20120175056A1/en
2017-02-07 Publication of US9561139B2 publication Critical patent/US9561139B2/en
The present application is a divisional of co-pending, commonly assigned, U.S. patent application Ser. No. 11/360,115 entitled “METHOD OF MAKING AN ABSORBENT COMPOSITE AND ABSORBENT ARTICLES EMPLOYING THE SAME,” filed Feb. 22, 2006, the disclosure of which is hereby incorporated herein by reference.
The backsheet is designed to prevent fluid from passing from the absorbent core through the backsheet and out of the absorbent article. The backsheet may be made out of an impermeable film that extends the full width of the article or a combination of cloth-like material and impermeable film. The backsheet may also have vapor transmission properties (“breathability”) that allow vapor to pass through the backsheet without releasing fluid stored in the absorbent core. The backsheet may also be made from a liquid impermeable but vapor transmittable non-woven material such as spunbond, melt-blow, spun-bond (“SMS”); spun-bond, melt-blown, melt-blown, spun-bond (“SMMS”); micro, nano, or splitable fibers; spun melt or spun laced; carded; and the like.
The novel article may further include a pair of longitudinally-extending, upstanding cuffs spaced laterally from the core, each the cuff including a folded portion of the top sheet and a longitudinally-extending absorbent composite secured within the folded portion, the longitudinally-extending absorbent composite comprising a first cuff fabric, a second cuff fabric bonded to the first cuff fabric, and particles adhered between the first and second fabric. The longitudinally extending absorbent composite may be sections of one continuous absorbent composite. The top sheet may be comprised of the first fabric of the absorbent composite. The absorbent core may comprise the absorbent composite. The absorbent composite of the core may further comprise particles positioned on the second fabric, and a third fabric bonded to the second fabric. The absorbent composite of the core may further comprises a third fabric positioned adjacent to the second fabric, a fourth fabric bonded to the third fabric, and particles adhered between the third and fourth fabrics. The second and third fabrics may be unitary.
An alternative embodiment of the novel absorbent article comprises a top sheet, a back sheet, an absorbent composite comprising a first fabric, a second fabric bonded to the first fabric, and an absorbent layer of particles adhered between the first and second fabric, wherein the absorbent layer is disposed between the top sheet and back sheet, and generally centrally at a location identified as a crotch region, the absorbent layer” providing an absorbent core for absorbing bodily exudates received in the crotch region.
The alternative embodiment may further comprise a pair of longitudinally-extending, upstanding cuffs spaced laterally from the absorbent core, each the cuff including a folded portion of the top sheet and a longitudinally-extending absorbent composite secured within the folded portion, the longitudinally-extending absorbent composite including a first cuff fabric, a second cuff fabric bonded to the first cuff fabric, and an absorbent layer of particles adhered between the first and second cuff fabric. Additionally, the absorbent composite located at the crotch region and the longitudinally extending absorbent composites of the cuffs may be sections of one continuous absorbent composite structure positioned about the crotch region.
FIG. 10 is an exploded view of the disposable article of FIG. 8,
FIG. 6 (a) through (q) show various bonding patterns contemplated by the inventive method. The bonding patterns may completely enclose an area, partially enclose an area, or provide local bonding zones. The lines and points indicate the bond sites. The solid lines depict bond lines. The bond lines may form open shapes or enclosed shapes, such as can be found in examples (a) and (c), which depict continuous bond lines that completely enclose pockets of SAP particles 135 or, as in example (g), separate distinct regions of the absorbent composite. The dashed lines, such as can be found in examples (b) and (m), are discontinuous bond patters that do not completely enclose pockets of SAP particles 135. In these configurations, the migration of dry SAP particles is inhibited by the adhesive and continuous or discontinuous bond patters. Discontinuous pond patters may be substituted for continuous bond patterns and vice versa. Further, though the FIG. 6 shows either continuous or discontinuous bond patters, combinations of discontinuous and continuous bond patters may be used.
Similarly, the inventive absorbent composite 195 may be utilized with or as the topsheet of an absorbent garment. The topsheet 50 is preferably soft, compliant, exhibits good strikethrough and a reduced tendency to rewet from a liquid pervious material. The topsheet 50 is placed in close proximity to the skin of the wearer when the diaper 10 is worn. In this way, such a topsheet 50 permits bodily discharges to rapidly penetrate it so as to flow toward the core 46 more quickly, but not allowing such discharges to flow back through the topsheet 50. The topsheet 50 may be constructed from any one of a wide range of liquid and vapor permeable hydrophilic materials. The surface(s) of the topsheet may be treated with a surfactant so as to facilitate liquid transfer therethrough, especially at a central zone or area of the topsheet located over the core and an inner surface of the core. The topsheet may also be coated with a substance having rash preventing or rash reducing properties (e.g., aloe vera).
Now turning to FIGS. 13 and 14, in yet another aspect of the invention, the inventive disposable absorbent article 10 utilizes a pair of containment walls or cuffs 34 which employ the absorbent composite 195. Each containment wall 34 is a longitudinally extending wall structure preferably positioned on each side of the core 46 and spaced laterally from the longitudinal center. The longitudinal ends of the walls 34 may be attached, for example, to the topsheet 50 in the front and rear waist regions 12 and
Preferably, the ends of the containment wall 34 are tacked down inwardly and attached, for example, by adhesive to the web structure. Such a construction effectively biases the containment wall 34 inwardly and is generally considered to cause containment wall 34 to exhibit improved leakage prevention properties.
1. A method of manufacturing a pulp-free composite sheet capable of stabilizing a layer of absorbent particles against migration, comprising the steps of:
positioning a first fabric to pass directly below a supply of absorbent particles to receive absorbent particles;
depositing absorbent particles on said first fabric, whereby a population of superabsorbent particles is released from the supply of superabsorbent particles and pass from the supply directly onto the first fabric below the supply, as the first fabric is conveyed and passes horizontally below the supply of superabsorbent particles fixed above the moving first fabric;
forming a plurality of arrangements of bond sites each of which extends between said first and second fabric, thereby sandwiching a discrete layer of pulp-free absorbent particles between said first and second fabrics; and
wherein said superabsorbent particles are secured between said first fabric and said second fabric; and
wherein said depositing absorbent particle comprises mixing absorbent particles with adhesive in the form of thermal plastic particles and depositing said absorbent particles mixed with adhesive on said first fabric, and wherein after forming said arrangement of bond sites, said bond sites and said adhesive stabilizes superabsorbent particles against migration.
2. The method of claim 1 wherein said particles comprise super absorbent particles, said method further comprising positioning the particles deposited on the first fabric, after depositing, and before forming the bond sites.
3. The method of claim 2, wherein adhesive is applied to the second fabric in a concentration sufficient to secure an effective amount of dry particles.
4. The method of claim 3, wherein the concentration of adhesive is between 12 and 50 grams per square meter.
5. The method of claim 2, further comprising the step of applying adhesive to said first fabric before absorbent particles are deposited on said first fabric, and wherein the total amount of adhesive engaging absorbent particles is between 1 and 100 grams per square meter.
6. The method of claim 2, wherein said layers of absorbent particles consists of super absorbent particles.
7. The method of claim 1 further comprising the step of forming at least one recessed area on said first fabric to receive said absorbent particles.
8. The method of claim 7, wherein said forming step comprises conforming the first fabric to a surface.
9. The method of claim 8, wherein the absorbent particles are super absorbent particles, said method further comprising the step of guiding the super absorbent particles into pockets formed by said arrangement of bond sites.
10. The method of claim 8, wherein suction is used to conform said first fabric to said surface.
after depositing said absorbent particles, conveying said first fabric with absorbent particles thereon along a horizontal direction before positioning said second fabric, and wherein during said depositing, the superabsorbent particles are released from the supply and pass along a direct vertical path clear of obstruction to a receipt location on the first fabric whereupon the superabsorbent particles are received.
12. The method of claim 1, wherein adhesive is applied to the first fabric with the superabsorbent particles and wherein said adhesive comprises thermal plastic particles, said method further comprising:
after said depositing super absorbent particles, melting the thermal plastic particles in the layers of superabsorbent particles.
13. The method of claim 1, wherein said forming bond sites step comprises forming bond lines that define pockets configured to contain individual layers of the absorbent particles, the layers being mutually spaced apart.
14. The method of claim 1, wherein said forming bond sites step comprises forming arrangements of discontinuous bond lines that partially enclose said layer of absorbent particles and, in respect to said layer of absorbent particles, inhibit particle migration.
15. The method of claim 1, wherein said forming bond sites step comprises forming a plurality of groups of spaced apart bond points each of which is arranged about said layer of absorbent particles.
16. The method of claim 1, wherein said forming bond sites step comprises providing bond sites configured to prevent straight line particle migration of more than 2 inches.
17. The method of claim 1, further comprising the step of coating the absorbent particles with a hydrophobic material.
18. The method of claim 1, wherein said forming said arrangement of bond sites includes passing the first fabric and second fabric through at least one calendar roll to thermally bond said first fabric and said second fabric to form said bond sites.
19. The method of claim 18, wherein said adhesive is thermal plastic material, said method further comprising:
after said positioning said second fabric and said forming bond sites, further conveying a composite having said first fabric and said second fabric sandwiching absorbent particles therebetween; and
applying heat to melt the thermal plastic material in said composite.
20. The method of claim 1, wherein a direct vertical path of the superabsorbent particles to the first fabric is generally normal to a horizontal surface receipt location on the first fabric and the first fabric is moving in a direction generally perpendicular to the direct vertical path, said vertical path being clear of obstructions between said receipt location on said first fabric and where said superabsorbent particles are released from said supply.
21. The method of claim 1, further comprising applying adhesive to the first fabric before said depositing superabsorbent particles.
22. The method of claim 21, wherein said adhesive is thermal plastic, said method further comprising applying heat to melt the thermal plastic material.
23. The method of claim 1, wherein said forming said arrangement of bond sites includes bonding the first fabric and the second fabric by ultrasonic bonding to form spaced apart bond points forming said bond sites.
24. A method of manufacturing an absorbent composite sheet capable of stabilizing a plurality of layers of absorbent particles against migration, comprising the steps of
positioning a first fabric to receive absorbent particles;
positioning absorbent particles on the first fabric including dispensing a population of loose absorbent particles from a supply of the absorbent particles and receiving the loose particles on the first fabric;
securing the absorbent particles relative to said first fabric;
positioning a second fabric over the absorbent particles; and
forming a plurality of groups of bond sites that join said first fabric to said second fabric, each of said groups being arranged about a discrete layer of absorbent particles, thereby sandwiching the layer of absorbent particles between the first and second fabrics, wherein the bond sites are discrete bond points spaced apart to inhibit the migration of the absorbent particles.
25. The method of claim 24, wherein the bond points are intermittently spaced about the layer of absorbent particles to define a pocket wherein said absorbent particles are secured to inhibit the migration of the absorbent particles.
26. The method of claim 25, wherein the layer of absorbent particles is a pulp-free layer consisting of super absorbent particles.
27. The method of claim 24, further comprising the step of forming shapes in said first fabric for receiving absorbent particles.
28. The method claim 24, further comprising the step of depositing on at least one of said first fabric and second fabric other particles selected from the group consisting of skin care particles, odor absorbing particles, binder particles, ion exchange particles, and combinations thereof.
29. The method of claim 24, wherein the absorbent particles are secured to the first fabric with thermal plastic adhesive.
30. The method of claim 24, wherein the step of securing the absorbent particles comprises mixing the absorbent particles with adhesive prior to said depositing.
31. The method of claim 30, wherein the step of securing the absorbent particles comprises applying additional adhesive to the deposited absorbent particles.
32. The method of claim 24, further comprising mixing adhesive with said absorbent particles in the form of thermal plastic material before said superabsorbent particles are deposited on the first fabric during said depositing; and
using an energy source positioned downstream of where the superabsorbent particles are deposited on the fabric to melt the thermal plastic material.
33. The method of claim 24, further comprising applying adhesive to the first fabric before said depositing superabsorbent particles.
34. The method of claim 33, wherein said adhesive is thermal plastic material, said method further comprising applying heat to melt the thermal plastic material.
35. The method of claim 24, wherein, during said depositing, the superabsorbent particles are released from the supply and pass from the supply directly onto the first fabric as the first fabric passes horizontally directly below the supply and wherein the supply is fixed above the moving first fabric and spaced vertically therefrom.
36. A method of manufacturing an absorbent core for a disposable absorbent article, said method comprising:
depositing absorbent particles on one of a first fabric and a second fabric by dispensing loose absorbent particles from a supply of the absorbent particles and receiving said loose absorbent particles on the surface of said first or second fabric;
positioning the first fabric relative to the second fabric with adhesive applied thereon and said absorbent particles disposed between the first and second fabrics, whereby said applied adhesive secure, at least partly, some of the absorbent particles; and
forming bond sites extending between the first fabric and the second fabric, wherein the bond sites are intermittently spaced apart bond points forming a bonding pattern composed of a plurality of groups of bond points each arranged about a discrete layer of pulp-free absorbent particles thereby forming a pocket in which the layer of absorbent particles is secured, the discrete layers of absorbent particles being pulp-free and mutually spaced apart.
37. The method of claim 36, wherein the layers of absorbent particles consist of said absorbent particles and wherein, during said dispensing, the superabsorbent particles are released from the supply and pass from the supply directly onto the first fabric as the first fabric passes horizontally directly below the supply and wherein the supply is fixed above the moving first fabric and spaced vertically therefrom.
prior to positioning the first fabric, conveying the first or second fabric with absorbent particles deposited thereon, whereby the first fabric engages the second fabric.
39. The method of claim 38, wherein conveying the first or second fabric includes moving the first or second fabric across a plane.
40. The method of claim 38, wherein said groups of bond points are positioned about said layer of absorbent particles to partially enclose said layer and inhibit particle migration, the groups of bond points forming gaps between spaced apart bond points and between said first and second fabrics.
US13/424,041 2006-02-22 2012-03-19 Method of making an absorbent composite and absorbent articles employing the same Active US9561139B2 (en)
US11/360,115 Division US8148598B2 (en) 2006-02-22 2006-02-22 Method of making an absorbent composite and absorbent articles employing the same
US14/134,001 Continuation US9757284B2 (en) 2006-02-22 2013-12-19 Method of making an absorbent composite and absorbent articles employing the same
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