U.S. patent application number 10/306097 was filed with the patent office on 2003-06-26 for absorbent article with stabilized absorbent structure.
This patent application is currently assigned to Kimberly-Clark Worldwide, Inc.. Invention is credited to Abuto, Frank P., Beitz, Mark J., Chakravarty, Jayant, Garvey, Michael J., Kressner, Bernhardt E., Rymer, Timothy J., Venturino, Michael B., Vogt, Robert E..
Application Number | 20030119400 10/306097 |
Document ID | / |
Family ID | 27488151 |
Filed Date | 2003-06-26 |
United States Patent
Application |
20030119400 |
Kind Code |
A1 |
Beitz, Mark J. ; et
al. |
June 26, 2003 |
Absorbent article with stabilized absorbent structure
Abstract
An absorbent article having a liner, an outer cover, and an
absorbent body disposed therebetween. The absorbent body includes a
non-woven absorbent structure having a length, a thickness, a width
and opposite side edges generally defining the width of the
structure. The thickness of the absorbent structure is non-uniform
along at least one of the length and the width of the absorbent
structure and the opposite side edges of the absorbent structure
are substantially uncut along the length of the absorbent
structure. The absorbent structure is of unitary construction of
absorbent fibers and binder fibers activated to form inter-fiber
bonds within the absorbent structure. In another embodiment, the
width of the absorbent structure is non-uniform along the length of
the absorbent structure and the opposite side edges of the
absorbent structure are substantially uncut along the length of the
absorbent structure.
Inventors: |
Beitz, Mark J.; (Appleton,
WI) ; Abuto, Frank P.; (Duluth, GA) ;
Chakravarty, Jayant; (Appleton, WI) ; Garvey, Michael
J.; (Appleton, WI) ; Rymer, Timothy J.;
(Appleton, WI) ; Venturino, Michael B.; (Appleton,
WI) ; Vogt, Robert E.; (Neenah, WI) ;
Kressner, Bernhardt E.; (Appleton, WI) |
Correspondence
Address: |
SENNIGER POWERS LEAVITT AND ROEDEL
ONE METROPOLITAN SQUARE
16TH FLOOR
ST LOUIS
MO
63102
US
|
Assignee: |
Kimberly-Clark Worldwide,
Inc.
|
Family ID: |
27488151 |
Appl. No.: |
10/306097 |
Filed: |
November 27, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10306097 |
Nov 27, 2002 |
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10034079 |
Dec 20, 2001 |
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10306097 |
Nov 27, 2002 |
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10034021 |
Dec 20, 2001 |
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10306097 |
Nov 27, 2002 |
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10037385 |
Dec 20, 2001 |
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10306097 |
Nov 27, 2002 |
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10033860 |
Dec 20, 2001 |
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Current U.S.
Class: |
442/327 |
Current CPC
Class: |
A61F 13/533 20130101;
A61F 2013/53024 20130101; A61F 13/15626 20130101; D01F 1/106
20130101; Y10T 442/697 20150401; D06M 10/003 20130101; A61F
2013/15357 20130101; Y10T 442/637 20150401; Y10T 428/27 20150115;
A61F 13/532 20130101; A61F 13/535 20130101; A61F 13/534 20130101;
A61F 13/536 20130101; A61F 2013/530364 20130101; A61F 2013/1543
20130101; A61L 15/60 20130101; A61F 13/8405 20130101; A61F
2013/530182 20130101; Y10T 442/60 20150401; Y10T 442/696 20150401;
Y10T 442/659 20150401; A61F 2013/15292 20130101; A61F 13/15203
20130101; A61F 2013/530218 20130101 |
Class at
Publication: |
442/327 |
International
Class: |
D04H 001/00 |
Claims
What is claimed is:
1. An absorbent article comprising: a liner adapted for contiguous
relationship with the wearer's body; an outer cover in generally
opposed relationship with the liner; and an absorbent body disposed
between the liner and the outer cover and comprising a non-woven
absorbent structure having a length, a thickness, a width and
opposite side edges generally defining the width of the structure,
the thickness of the absorbent structure being non-uniform along at
least one of the length and the width of the absorbent structure,
the opposite side edges of the absorbent structure being
substantially uncut along the length of the absorbent structure,
said absorbent structure being of unitary construction and
comprising absorbent fibers and binder fibers activated to form
inter-fiber bonds within the absorbent structure.
2. An absorbent article as set forth in claim 1 wherein the
absorbent structure is airformed.
3. An absorbent article as set forth in claim 1 wherein the
absorbent structure has an outer surface and a core, said absorbent
structure having less than about 5 times more oxidation at its
outer surface than at its core.
4. An absorbent article as set forth in claim 1 wherein the binder
fibers of the absorbent structure have a melting point equal to or
less than about 110.degree. C.
5. An absorbent article as set forth in claim 1 wherein the binder
fibers of the absorbent structure have an energy receptive additive
having a dielectric loss equal to or greater than about 0.5.
6. An absorbent article as set forth in claim 1 wherein the
concentration of binder fibers in the absorbent structure is
non-uniform along at least one of the length, the width and the
thickness of the structure.
7. An absorbent article as set forth in claim 1 wherein the
absorbent structure has a density, said density being non-uniform
along at least one of the length, the width and the thickness of
the absorbent structure.
8. An absorbent article as set forth in claim 1 wherein the binder
fibers are multi-component fibers in which at least one binder
fiber component has a melt temperature that is lower than a melt
temperature of at least one other binder fiber component.
9. An absorbent article as set forth in claim 1 wherein the width
of the absorbent structure is non-uniform along the length of the
non-woven structure.
10. An absorbent article as set forth in claim 1 wherein the
absorbent structure has a permeability throughout said absorbent
structure of greater than about 20 square microns.
11. An absorbent article as set forth in claim 10 wherein the
permeability of at least a portion of the absorbent structure is
greater than or equal to about 40 square microns.
12. An absorbent article as set forth in claim 11 wherein the
permeability of said portion of the absorbent structure is greater
than or equal to about 60 square microns.
13. An absorbent article comprising: a liner adapted for contiguous
relationship with the wearer's body; an outer cover in generally
opposed relationship with the liner; and an absorbent body disposed
between the liner and the outer cover and comprising a non-woven
absorbent structure comprising absorbent fibers and binder fibers
activated to form inter-fiber bonds within the absorbent structure,
the binder fibers being multi-component fibers in which at least
one binder fiber component has a melt temperature that is lower
than a melt temperature of at least one other binder fiber
component, the absorbent structure having a length, a thickness, a
width and opposite side edges generally defining the width of the
structure, the width of the absorbent structure being non-uniform
along the length of the absorbent structure, the opposite side
edges of the absorbent structure being substantially uncut along
the length of the absorbent structure.
14. An absorbent article as set forth in claim 13 wherein the
non-woven structure is of unitary construction.
15. An absorbent article as set forth in claim 13 wherein the
non-woven structure is airformed.
16. An absorbent article comprising: a liner adapted for contiguous
relationship with the wearer's body; an outer cover in generally
opposed relationship with the liner; and an absorbent body disposed
between the liner and the outer cover and comprising a non-woven
absorbent structure having a length, a thickness, and a width, the
thickness of the absorbent structure being non-uniform along at
least one of the length and the width of the absorbent structure,
said absorbent structure being of unitary construction and
comprising absorbent fibers and binder fibers activated to form
inter-fiber bonds within the absorbent structure, said absorbent
structure being unmolded during and after activation of the binder
fibers.
17. An absorbent article as set forth in claim 16 wherein the width
of the absorbent structure is non-uniform along the length of the
non-woven structure.
18. An absorbent article comprising: a liner adapted for contiguous
relationship with the wearer's body; an outer cover in generally
opposed relationship with the liner; and an absorbent body disposed
between the liner and the outer cover and comprising a non-woven
absorbent structure having a length, a width, and a basis weight,
the width of the absorbent structure being non-uniform along the
length of the non-woven structure, the basis weight of the
absorbent structure being non-uniform along at least one of the
length and the width of the absorbent structure, said absorbent
structure being of unitary construction and comprising absorbent
fibers and binder fibers activated to form inter-fiber bonds within
the absorbent structure, the absorbent structure having opposite
major faces which are substantially unmolded during and after
activation of the binder fibers.
19. An absorbent article comprising: a liner adapted for contiguous
relationship with the wearer's body; an outer cover in generally
opposed relationship with the liner; and an absorbent body disposed
between the liner and the outer cover and comprising a non-woven
absorbent structure comprising absorbent fibers and binder fibers
activated to form inter-fiber bonds within the absorbent structure,
the binder fibers being multi-component fibers in which at least
one binder fiber component has a melt temperature that is lower
than a melt temperature of at least one other binder fiber
component, the absorbent structure having a length, a thickness, a
width and opposite side edges generally defining the width of the
structure, the width of the absorbent structure being non-uniform
along the length of the absorbent structure, the side edges each
having a surface contour no portion of which is concave.
20. An absorbent article as set forth in claim 19 wherein each side
edge of the non-woven structure has a surface contour which is
generally convex.
21. An absorbent article comprising: a liner adapted for contiguous
relationship with the wearer's body; an outer cover in generally
opposed relationship with the liner; and an absorbent body disposed
between the liner and the outer cover and comprising a non-woven
absorbent structure having a length, a thickness, a width, opposite
side edges generally defining the width of the structure, and
opposite major surfaces, the thickness of the absorbent structure
being non-uniform across the width of the structure along at least
a portion of the length of said structure, said absorbent structure
having a brightness gradient across its width at said portion in
the range of about 0.5 to about 3.0 gray units/mm as determined by
an absorbent structure brightness test.
22. An absorbent article comprising: a liner adapted for contiguous
relationship with the wearer's body; an outer cover in generally
opposed relationship with the liner; and an absorbent body disposed
between the liner and the outer cover and comprising a non-woven
absorbent structure having a length, a thickness, a width and
opposite side edges generally defining the width of the structure,
the width of the absorbent structure being non-uniform along the
length of the absorbent structure, the side edges of the absorbent
structure having an edge brightness profile defined by a second
order polynomial function as determined by an edge brightness test,
said function having a coefficient "a" of the X.sup.2 term in the
range of about -15 to about 20 and a coefficient "b" of the X term
in the range of about 10 to about 40.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part patent
application of U.S. patent applications Ser. No. 10/034,079
entitled Targeted Bonding Fibers for Stabilized Absorbent
Structures; Ser. No. 10/034,021 entitled Absorbent Structures
Having Low Melting Fibers; Ser. No. 10/037,385 entitled Method and
Apparatus for Making On-Line Stabilized Absorbent Materials; and
Ser. No. 10/033,860 entitled Targeted On-Line Stabilized Absorbent
Structures; all of which were filed on Dec. 20, 2001 and are fully
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to absorbent
articles, such as those used as personal care products, and more
particularly to such an absorbent article having an absorbent body
comprised at least in part of a stabilized nonwoven absorbent
structure.
[0003] Absorbent articles find widespread use as personal care
products such as diapers, children's toilet training pants, adult
incontinence garments, medical garments, sanitary napkins and the
like, as well as surgical bandages and sponges. These articles
absorb and contain body waste and are typically disposable in the
sense that they are intended to be discarded after a limited period
of use; i.e., the articles are not intended to be laundered or
otherwise restored for reuse. Conventional disposable absorbent
articles comprise an absorbent body disposed between a liner
adapted for contiguous relationship with the wearer's skin and an
outer cover for inhibiting liquid body waste absorbed by the
absorbent body from leaking out of the article. The liner of the
absorbent article is typically liquid permeable to permit liquid
body waste to pass therethrough for absorption by the absorbent
body.
[0004] In one general practice of forming fibrous webs (commonly
referred to as airforming) for use as an absorbent body in such
absorbent articles, discrete fibers such as cellulosic or other
suitable absorbent fibers are introduced into an airforming device
along with particulate or fibrous superabsorbent material. The
absorbent fibers and superabsorbent particles are entrained in an
air stream within the airforming device and directed onto a
foraminous forming surface upon which the mixture of absorbent
fibers and superabsorbent particles are collected to form an
absorbent fibrous web or structure.
[0005] Airforming devices employed in high-speed commercial
operations typically have a forming surface constructed of a wire
screen or fluted grid, and one or more form members which, together
with the wire screen or fluted grid, generally define the length,
width and thickness profiles of the absorbent structure to be
formed on the forming surface. A pneumatic flow mechanism, such as
a vacuum suction system, draws the airentrained fiber stream within
the airforming device onto the forming surface, and pass the
airflow through the forming surface has been employed in high-speed
commercial operations. By using such an airforming device,
absorbent structures have been formed with gradations in basis
weight (e.g., thickness) along the length and/or width of the
absorbent structure, and have also been formed to have a generally
non-uniform width.
[0006] While airformed absorbent structures that comprise a mixture
of absorbent fibers and superabsorbent material have proven useful
in making absorbent bodies of preferred shapes and sizes for
various absorbent articles, further improvement is desired. More
particularly, such absorbent structures lack the structural
integrity or stability to maintain its original shape (e.g.,
length, width and particularly thickness) following repeated liquid
insults by the wearer.
[0007] To this end, it is known to use a conventional airlaying
process to form a stabilized absorbent web or structure in which
binder materials have been added to the structure. Such binder
materials have included adhesives, powders, netting, and binder
fibers. The binder fibers have included one or more of the
following types of fibers: homofilaments, heat-fusible fibers,
bicomponent fibers, meltblown polyethylene fibers, meltblown
polypropylene fibers, and the like.
[0008] In conventional airlaying systems, binder fibers are mixed
with absorbent fibers and superabsorbent materials and the mixture
is then deposited onto a porous forming surface by using a vacuum
system to draw the fibers onto the forming surface. The structure
formed on the forming surface is then heated to activate the binder
fibers whereby at least a portion of the binder fibers melt and
form inter-fiber bonds with the absorbent fibers to form a
stabilized structure.
[0009] Such conventional airlaying systems, however, have been
limited with regard to the lengths of the binder fibers that can be
efficiently employed. In the operation of the conventional systems,
the lengths of the binder fibers have typically been 6 mm or less.
Attempts to use longer binder fibers have caused plugging of
distribution screens, non-uniform distribution of fibers, fiber
clumping, and other basis weight uniformity problems. Such
airlaying systems have also required the use of excessive amounts
of energy. Where the binder fibers are heat-activated to provide
the stabilized web structure, it has been necessary to subject the
structure to an excessively long heating time to adequately heat
the binder fibers. For instance, typical heating times with
through-air bonding systems are in the range of 7-8 seconds.
Additionally, it has been necessary to subject the fibrous web to
an excessively long cooling time, such as during roll storage in
warehouses, to establish and preserve the desired stabilized
structure prior to further processing operations.
[0010] As a result, conventional airlaying systems have been
inadequate for manufacturing stabilized absorbent structures
directly in-line on consumer product converting machines at
high-speeds. Rather, where stabilized absorbent structures are
desired for use in making absorbent bodies for absorbent articles,
the common approach has been to manufacture wider than needed
stabilized webs off-line whereby the webs are rolled and stored for
subsequent use in separate manufacturing machines.
[0011] One particular disadvantage of such an approach is that
conventional airlaying systems are limited as to dimensioning of
the stabilized structure formed thereby. More particularly, the
stabilized structure formed by existing airlaying systems has both
a uniform width (e.g., straight side edges) and a substantially
uniform basis weight and thickness. Where a shaped absorbent
structure having a non-uniform width is desired, such as an
absorbent structure having a narrowed crotch region, the previously
formed stabilized web must be unrolled and the side edges of the
web must be cut to provide the desired width profile. Such cutting
and shaping of the selected segments of the stabilized web results
in excessive wasted amounts of the stabilized web, and has
excessively complicated the manufacturing operations. In addition,
conventional systems have resulted in excessive costs associated
with the shipping, storage, and roll handling of the relatively low
density materials.
[0012] Also, where a non-uniform basis weight or thickness is
desired, e.g., to provide the absorbent structure with a targeted
area of increased basis weight for increased absorbing capacity, a
smaller (e.g., narrower) layer must be cut from one stabilized web
and then overlayed and bonded onto a larger stabilized web to
increase the basis weight of the absorbent structure at the
targeted area. This requires additional steps and even further
complicates manufacturing operations.
SUMMARY OF THE INVENTION
[0013] In general, one embodiment of an absorbent article of the
present invention comprises a liner adapted for contiguous
relationship with the wearer's body and an outer cover in generally
opposed relationship with the liner. An absorbent body is disposed
between the liner and the outer cover and comprises a non-woven
absorbent structure having a length, a thickness, a width and
opposite side edges generally defining the width of the structure.
The thickness of the absorbent structure is non-uniform along at
least one of the length and the width of the absorbent structure
and the opposite side edges of the absorbent structure are
substantially uncut along the length of the absorbent structure.
The absorbent structure is of unitary construction and comprises
absorbent fibers and binder fibers activated to form inter-fiber
bonds within the absorbent structure.
[0014] In another embodiment, the absorbent article generally
comprises a liner adapted for contiguous relationship with the
wearer's body and an outer cover in generally opposed relationship
with the liner. An absorbent body is disposed between the liner and
the outer cover and comprises a non-woven absorbent structure
comprising absorbent fibers and binder fibers activated to form
inter-fiber bonds within the absorbent structure. The binder fibers
are multi-component fibers in which at least one binder fiber
component has a melt temperature that is lower than a melt
temperature of at least one other binder fiber component. The
absorbent structure has a length, a thickness, a width and opposite
side edges generally defining the width of the structure. The width
of the absorbent structure is non-uniform along the length of the
absorbent structure and the opposite side edges of the absorbent
structure are substantially uncut along the length of the absorbent
structure.
[0015] In another embodiment, the absorbent article generally
comprises a liner adapted for contiguous relationship with the
wearer's body and an outer cover in generally opposed relationship
with the liner. An absorbent body is disposed between the liner and
the outer cover and comprises a non-woven absorbent structure
having a length, a thickness, and a width. The thickness of the
absorbent structure is non-uniform along at least one of the length
and the width of the absorbent structure. The absorbent structure
is of unitary construction and comprises absorbent fibers and
binder fibers activated to form inter-fiber bonds within the
absorbent structure. The absorbent structure is unmolded during and
after activation of the binder fibers.
[0016] In yet another embodiment, the absorbent article generally
comprises a liner adapted for contiguous relationship with the
wearer's body and an outer cover in generally opposed relationship
with the liner. An absorbent body is disposed between the liner and
the outer cover and comprises a non-woven absorbent structure
having a length, a width, and a basis weight. The width of the
absorbent structure is non-uniform along the length of the
non-woven structure and the basis weight of the absorbent structure
is non-uniform along at least one of the length and the width of
the absorbent structure. The absorbent structure is of unitary
construction and comprises absorbent fibers and binder fibers
activated to form inter-fiber bonds within the absorbent structure.
The absorbent structure has opposite major faces which are
substantially unmolded during and after activation of the binder
fibers.
[0017] In still another embodiment, the absorbent article generally
comprises a liner adapted for contiguous relationship with the
wearer's body and an outer cover in generally opposed relationship
with the liner. An absorbent body is disposed between the liner and
the outer cover and comprises a non-woven absorbent structure
comprising absorbent fibers and binder fibers activated to form
inter-fiber bonds within the absorbent structure. The binder fibers
are multi-component fibers in which at least one binder fiber
component has a melt temperature that is lower than a melt
temperature of at least one other binder fiber component. The
absorbent structure has a length, a thickness, a width and opposite
side edges generally defining the width of the structure, the width
of the absorbent structure being non-uniform along the length of
the absorbent structure and the side edges each having a surface
contour no portion of which is concave.
[0018] In another embodiment, the absorbent article generally
comprises a liner adapted for contiguous relationship with the
wearer's body and an outer cover in generally opposed relationship
with the liner. An absorbent body is disposed between the liner and
the outer cover and comprises a non-woven absorbent structure
having a length, a thickness, a width, opposite side edges
generally defining the width of the structure, and opposite major
surfaces. The thickness of the absorbent structure is non-uniform
across the width of the structure along at least a portion of the
length of the structure. The absorbent structure has a brightness
gradient across its width at said portion in the range of about 0.5
to about 3.0 gray units/mm as determined by an absorbent structure
brightness test.
[0019] In yet another embodiment, the absorbent article generally
comprises a liner adapted for contiguous relationship with the
wearer's body and an outer cover in generally opposed relationship
with the liner. An absorbent body is disposed between the liner and
the outer cover and comprises a non-woven absorbent structure
having a length, a thickness, a width and opposite side edges
generally defining the width of the structure. The width of the
absorbent structure is non-uniform along the length of the
absorbent structure and the side edges of the absorbent structure
have an edge brightness profile defined by a second order
polynomial function as determined by an edge brightness test. The
function has a coefficient "a" of the X.sup.2 term in the range of
about -15 to about 20 and a coefficient "b" of the X term in the
range of about 10 to about 40.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a plan view of an absorbent article of the present
invention illustrated in the form of a diaper shown unfastened and
laid flat;
[0021] FIG. 2 is an exploded cross section taken generally in the
plane including line 2-2 of FIG. 1;
[0022] FIG. 3 is a perspective view of the diaper shown as
worn;
[0023] FIG. 4 is a longitudinal cross-section of an absorbent
structure of the diaper of FIG. 1 taken generally on the
longitudinal axis thereof;
[0024] FIG. 5 is a schematic perspective of apparatus for forming
an absorbent structure of the present invention;
[0025] FIG. 6 is an enlarged side elevation of an airforming device
of the apparatus of FIG. 5;
[0026] FIG. 7 is a fragmentary cross-section of the airforming
device of FIG. 6;
[0027] FIG. 8 is a schematic perspective of a forming drum and
forming surface of the airforming device of FIG. 6;
[0028] FIG. 9 is an enlarged schematic of a portion of the forming
drum and forming surface;
[0029] FIG. 10 is a schematic perspective of a longitudinal
cross-section taken through a portion of the forming drum and
forming surface;
[0030] FIG. 11 is a schematic cross-sectional profile of a cut side
edge of a prior art stabilized absorbent structure;
[0031] FIG. 12 is a schematic cross-sectional profile of an uncut
side edge of a stabilized absorbent structure of the present
invention;
[0032] FIG. 13 is a photograph of the cross-sectional profile of
FIG. 12;
[0033] FIG. 14 is a photograph of the cross-sectional profile of
FIG. 11;
[0034] FIG. 15 is a cross-section of a permeability test apparatus;
and
[0035] FIG. 16 is cross-section taken in the plane of line 16-16 of
FIG. 15.
[0036] Corresponding reference characters indicate corresponding
parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] Referring now to the drawings and in particular to FIG. 1,
one example of an absorbent article constructed in accordance with
the present invention is illustrated in the form of a diaper, which
is indicated in its entirety by the reference numeral 21. As used
herein, an absorbent article refers to an article which may be
placed against or in proximity to the body of the wearer (e.g.,
contiguous to the body) to absorb and/or retain various waste
discharged from the body. Some absorbent articles, such as
disposable absorbent articles, are intended to be discarded after a
limited period of use instead of being laundered or otherwise
restored for reuse. It is contemplated, however, that the
principles of the present invention have application in garments
(including reusable garments) and other absorbent articles. For
example, the principles of the present invention may be
incorporated into children's training pants and other infant and
child care products, adult incontinence garments and other adult
care products, medical garments, sanitary napkins and other
feminine care products and the like, as well as surgical bandages
and sponges.
[0038] The diaper 21 is shown in FIG. 1 in an unfolded and
laid-flat condition to illustrate a longitudinal axis X and a
lateral axis Y of the diaper. The diaper 21 generally comprises a
central absorbent assembly 23 extending longitudinally from a front
(e.g., anterior) region 25 of the diaper through a crotch (e.g.,
central) region 27 to a back (e.g., posterior) region 29 of the
diaper. The central absorbent assembly 23 is generally I-shaped,
and more particularly hourglass shaped, and has contoured,
laterally opposite side edges 31 and longitudinally opposite front
and rear waist edges or ends, respectively designated 33 and 35. It
is understood, however, that the diaper 21 may have other shapes,
such as a rectangular shape or a T-shape without departing from the
scope of the present invention. The side edges 31 of the diaper 21
extend longitudinally from the front region 25 through the crotch
region 27 to the back region 29 for forming transversely spaced leg
openings 37 (FIG. 3) of the diaper when worn.
[0039] The front region 25 generally includes the portions of the
central absorbent assembly 23 which extend over the wearer's lower
abdominal region and the back region 29 generally includes the
portions of the central absorbent assembly which extend over the
wearer's lower back region. The crotch region 27 includes the
portion extending longitudinally through the wearer's crotch from
the front region 25 to the back region 29 and laterally between the
wearer's legs. As worn on the wearer's body (FIG. 3), the diaper 21
further defines a central waist opening 43 and the leg openings
37.
[0040] With particular reference to FIG. 2, the central absorbent
assembly 23 of the diaper 21 comprises an outer cover, generally
indicated at 49, a bodyside liner 51 positioned in facing relation
with the outer cover, and an absorbent body, generally indicated at
53, disposed between the outer cover and the liner. The outer cover
49 of the illustrated embodiment generally defines the length and
width of the diaper 21. The absorbent body 53 has a length and
width which are less than the respective length and width of the
outer cover 49 such that the outer cover extends both
longitudinally and laterally out beyond the sides and ends of the
absorbent body. The bodyside liner 51 may be generally coextensive
with the outer cover 49, or may instead overlie an area which is
larger (and would thus generally define the length and/or width of
the diaper 21) or smaller than the area of the outer cover 49, as
desired. In other words, the bodyside liner 51 is preferably in
superposed relation with the outer cover 49 but may not necessarily
be coextensive with the outer cover.
[0041] In one embodiment, the outer cover 49 is stretchable and may
or may not be somewhat elastic. More particularly, the outer cover
49 is sufficiently extensible such that once stretched under the
weight of the insulted absorbent body, the outer cover will not
retract substantially back toward its original position. However,
it is contemplated that the outer cover 49 may instead be generally
non-extensible and remain within the scope of this invention.
[0042] The outer cover 49 may be a multi-layered laminate structure
to provide desired levels of extensibility as well as liquid
impermeability and vapor permeability. For example, the outer cover
49 of the illustrated embodiment is of two-layer construction,
including an outer layer 55 constructed of a vapor permeable
material and an inner layer 57 constructed of a liquid impermeable
material, with the two layers being secured together by a suitable
laminate adhesive 59. It is understood, however, that the outer
cover 49 may instead be constructed of a single layer of liquid
impermeable material, such as a thin plastic film constructed of
materials such as those from which the inner layer 57 is
constructed as described later herein, without departing from the
scope of this invention. The liquid impermeable inner layer 57 of
the outer cover 49 can be either vapor permeable (i.e.,
"breathable") or vapor impermeable.
[0043] The bodyside liner 51 is preferably pliable, soft feeling,
and nonirritating to the wearer's skin, and is employed to help
isolate the wearer's skin from the absorbent body 53. The liner 51
is less hydrophilic than the absorbent body 53 to present a
relatively dry surface to the wearer, and is sufficiently porous to
be liquid permeable to thereby permit liquid to readily penetrate
through its thickness. A suitable bodyside liner 51 may be
manufactured from a wide selection of web materials, but is
preferably capable of stretching in at least one direction (e.g.,
longitudinal or lateral). In particular embodiments, the bodyside
liner 51 is desirably extensible and capable of extending along
with the outer cover 49 for desired fit of the diaper on the
wearer.
[0044] Fastener tabs 65 (FIGS. 1 and 3) are secured to the central
absorbent assembly 23 generally at the back region 29 thereof with
the tabs extending laterally out from the opposite side edges 31 of
the assembly. The fastener tabs 65 may be attached to the outer
cover 49, to the bodyside liner 51, between the outer cover and
liner, or to other components of the diaper 21. The tabs 65 may
also be elastic or otherwise rendered elastomeric. For example, the
fastener tabs 65 may be an elastomeric material such as a
neck-bonded laminate (NBL) or stretch-bonded laminate (SBL)
material.
[0045] Methods of making such materials are well known to those
skilled in the art and are described in U.S. Pat. No. 4,663,220
issued May 5, 1987 to Wisneski et al., U.S. Pat. No. 5,226,992
issued Jul. 13, 1993 to Morman, and European Patent Application No.
EP 0 217 032 published on Apr. 8, 1987 in the names of Taylor et
al., the disclosures of which are hereby incorporated by reference.
Examples of articles that include selectively configured fastener
tabs are described in U.S. Pat. No. 5,496,298 issued Mar. 5, 1996
to Kuepper et al.; U.S. Pat. Nos. 5,540,796 to Fries; and 5,595,618
to Fries; the disclosures of which are also incorporated herein by
reference. Alternatively, the fastener tabs 65 may be formed
integrally with a selected diaper component. For example, the tabs
65 may be formed integrally with the inner or outer layer 57, 55 of
the outer cover 49, or with the bodyside liner 51.
[0046] Fastening components, such as hook and loop fasteners,
designated 71 and 72 respectively, are employed to secure the
diaper 21 on the body of a child or other wearer. Alternatively,
other fastening components (not shown), such as buttons, pins,
snaps, adhesive tape fasteners, cohesives, mushroom-and-loop
fasteners, or the like, may be employed. Desirably, the
interconnection of the fastening components 71, 72 is selectively
releasable and re-attachable. In the illustrated embodiment, the
hook fasteners 71 are secured to and extend laterally out from the
respective fastener tabs 65 at the back region 29 of the diaper 21.
However, it is understood that the fastener tabs 65 may be formed
of a hook material and thus comprise the hook fasteners 71 without
departing from the scope of this invention. The loop fastener 72 of
the illustrated embodiment is a panel of loop material secured to
the outer cover 49 at the front region 25 of the diaper 21 to
provide a "fasten anywhere" mechanical fastening system for
improved fastening of the hook fasteners 71 with the loop
fastener.
[0047] The loop material may include a pattern-unbonded non-woven
fabric having continuous bonded areas that define a plurality of
discrete unbonded areas. The fibers or filaments within the
discrete unbonded areas of the fabric are dimensionally stabilized
by the continuous bonded areas that encircle or surround each
unbonded area, such that no support or backing layer of film or
adhesive is required. The unbonded areas are specifically designed
to afford spaces between fibers or filaments within the unbonded
areas that remain sufficiently open or large to receive and engage
hook elements of the complementary hook fasteners 71. In
particular, a pattern-unbonded non-woven fabric or web may include
a spunbond nonwoven web formed of single component or
multi-component melt-spun filaments. For example, the loop material
may be a laminated structure including a polyethylene component and
a polypropylene component adhesively bonded together with the
polypropylene component facing outward away from the outer cover 49
to receive the hook fasteners 71. Examples of suitable
pattern-unbonded fabrics are described in U.S. Pat. No. 5,858,515
issued Jan. 12, 1999 to T. J. Stokes et al. and entitled
PATTERN-UNBONDED NON-WOVEN WEB AND PROCESS FOR MAKING THE SAME; the
entire disclosure of which is incorporated herein by reference in a
manner that is consistent herewith.
[0048] The diaper 21 shown in FIG. 1 also comprises a pair of
containment flaps, generally indicated at 75, configured to provide
a barrier to the lateral flow of body exudates. The containment
flaps 75 are located generally adjacent the laterally opposite side
edges 31 of the diaper 21 and, when the diaper is laid flat as
shown in FIGS. 1 and 2, extend inward toward the longitudinal axis
X of the diaper. Each containment flap 75 typically has a free, or
unattached end 77 free from connection with the bodyside liner 51
and other components of the diaper 21. Elastic strands 79 disposed
within the flaps 75 adjacent the unattached ends thereof urge the
flaps toward an upright, perpendicular configuration in at least
the crotch region 27 of the diaper 21 to form a seal against the
wearer's body when the diaper is worn. The containment flaps 75 may
extend longitudinally the entire length of the absorbent body 53 or
they may extend only partially along the length of the absorbent
body. When the containment flaps 75 are shorter in length than the
absorbent body 53, the flaps can be selectively positioned anywhere
between the side edges 31 of the diaper 21 in the crotch region 27.
In a particular aspect of the invention, the containment flaps 75
extend the entire length of the absorbent body 53 to better contain
the body exudates.
[0049] Such containment flaps 75 are generally well known to those
skilled in the art and therefore will not be further described
herein except to the extent necessary to describe the present
invention. As an example, suitable constructions and arrangements
for containment flaps 75 are described in U.S. Pat. No. 4,704,116
issued Nov. 3, 1987, to K. Enloe, the disclosure of which is hereby
incorporated by reference. The diaper 21 may also incorporate other
containment components in addition to or instead of the containment
flaps 75. For example, while not shown in the drawings, other
suitable containment components may include, but are not limited
to, elasticized waist flaps, foam dams in the front, back and/or
crotch regions, and the like.
[0050] The various components of the diaper 21 are assembled
together using a suitable form of attachment, such as adhesive,
sonic bonds, thermal bonds or combinations thereof. In the
illustrated embodiment, the outer cover 49 and absorbent body 53
are secured to each other with lines of adhesive 81, such as a hot
melt or pressure-sensitive adhesive. The bodyside liner 51 is also
secured to the outer cover 49 and may also be secured to the
absorbent body 53 using the same forms of attachment.
[0051] The bodyside liner 51 may be secured to the outer cover 49
at the lateral edge margins of the crotch region 27, but at least
the central portion is free of such connection. Rather than being
entirely free of such connection, the bodyside liner 51 may be
secured to the absorbent body 53 in the crotch region 27 by a light
adhesive 83 which will break away in use. Preferably, securement of
the bodyside liner 51 to the outer cover 49 is limited to overlying
peripheral edge margins of the two to promote independent
stretching movement of the liner and cover relative to each other.
If the diaper 21 is to be sold in a pre-fastened condition, the
diaper may also have passive bonds (not shown) which join the back
region 29 with the front region 25.
[0052] The diaper 21 can also include a surge management layer (not
shown) which helps to decelerate and diffuse surges or gushes of
liquid that may be rapidly introduced into the absorbent body 53.
Desirably, the surge management layer can rapidly accept and
temporarily hold the liquid prior to releasing the liquid to the
absorbent structure. In the illustrated embodiment, for example, a
surge layer can be located between the absorbent body 53 and the
bodyside liner 51. Examples of suitable surge management layers are
described in U.S. Pat. No. 5,486,166 entitled FIBROUS NON-WOVEN WEB
SURGE LAYER FOR PERSONAL CARE ABSORBENT ARTICLES AND THE LIKE by C.
Ellis and D. Bishop, which issued Jan. 23, 1996, and U.S. Pat. No.
5,490,846 entitled IMPROVED SURGE MANAGEMENT FIBROUS NONWOVEN WEB
FOR PERSONAL CARE ABSORBENT ARTICLES AND THE LIKE by C. Ellis and
R. Everett, which issued Feb. 13, 1996, the entire disclosures of
which are hereby incorporated by reference in a manner that is
consistent herewith.
[0053] To provide improved fit and to help further reduce leakage
of body exudates from the diaper 21, elastic components are
typically incorporated therein, particularly at the waist area and
the leg areas. For example, the diaper 21 of the illustrated
embodiment has waist elastic components 85 (FIG. 3) and leg
elastics 87 (FIGS. 1 and 2). The waist elastic components 85 are
configured to gather and shirr the end margins of the diaper 21 to
provide a resilient, comfortable close fit around the waist of the
wearer and the leg elastics 87 are configured to gather and shirr
the side margins of the diaper at the leg openings 37 to provide a
close fit around the wearer's legs.
[0054] Examples of other diaper 21 configurations suitable for use
in connection with the instant application that may or may not
include diaper components similar to those described previously are
described in U.S. Pat. No. 4,798,603 issued Jan. 17, 1989, to Meyer
et al.; U.S. Pat. No. 5,176,668 issued Jan. 5, 1993, to Bernardin;
U.S. Pat. No. 5,176,672 issued Jan. 5, 1993, to Bruemmer et al.;
U.S. Pat. No. 5,192,606 issued Mar. 9, 1993, to Proxmire et al.,
U.S. Pat. No. 5,509,915 issued Apr. 23, 1996 to Hanson et al., U.S.
Pat. No. 5,993,433 issued Nov. 30, 199 to St. Louis et al., and
U.S. Pat. No. 6,248,097 issued Jun. 19, 2001 to Beitz et al., the
disclosures of which are herein incorporated by reference.
[0055] In accordance with the present invention, the absorbent body
53 at least in part comprises a stabilized non-woven absorbent
structure 101 (FIG. 4) formed from a mixture of absorbent fibers,
superabsorbent material (the absorbent fibers and superabsorbent
material together broadly defining an absorbent material within the
absorbent structure) and binder fibers (broadly, a binding
material) which are activatable as will be described to form
inter-fiber bonds within the absorbent structure for stabilizing
the absorbent structure. The absorbent fibers may be provided by
various types of wettable, hydrophilic fibrous material. For
example, suitable absorbent fibers 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 or polyamide fibers; and
synthetic fibers composed of a nonwettable thermoplastic polymer,
such as polypropylene fibers, which have been hydrophilized by
appropriate means. The fibers may be hydrophilized, for example, by
treatment with silica, treatment with a material that has a
suitable hydrophilic moiety and is not readily removable from the
fiber, or by sheathing the nonwettable, hydrophobic fiber with a
hydrophilic polymer during or after the formation of the fiber. For
the present invention, it is contemplated that selected blends of
the various types of fibers mentioned above may also be
employed.
[0056] Suitable sources of absorbent fibers may include cellulosic
fibers including: wood fibers, such as bleached kraft softwood or
hardwood, high-yield wood fibers, and ChemiThermoMechanical Pulp
fibers; bagasse fibers; milkweed fluff fibers; wheat straw; kenaf;
hemp; pineapple leaf fibers; or peat moss. High-yield fibers, such
as BCTMP (Bleached ChemiThermal Mechanical Pulp) fibers, can be
flash-dried and compressed into densified pads. The high-yield
fiber can expand to a higher loft when wetted, and can be used for
the absorbent fiber material. Other absorbent fibers, such as
regenerated cellulose and curled chemically stiffened cellulose
fibers may also be densified to form absorbent structures that can
expand to a higher loft when wetted.
[0057] As an example, suitable wood pulps include standard softwood
fluffing grade such as NB-416 (Weyerhaeuser Corporation, Tacoma,
Wash., U.S.A.) and CR-1654 (US Alliance Pulp Mills, Coosa, Ala.,
U.S.A.), bleached kraft softwood or hardwood, high-yield wood
fibers, ChemiThermoMechanical Pulp fibers and Bleached Chemithermal
Mechanical Pulped (BCTMP). Pulp may be modified in order to enhance
the inherent characteristics of the fibers and their
processability. Curl may be imparted to the fibers by conventional
methods including chemical treatment or mechanical twisting. Pulps
may also be stiffened by the use of crosslinking agents such as
formaldehyde or its derivatives, glutaraldehyde, epichlorohydrin,
methylolated compounds such as urea or urea derivatives,
dialdehydes such as maleic anhydride, non-methylolated urea
derivatives, citric acid or other polycarboxylic acids. Some of
these agents are less preferable than others due to environmental
and health concerns.
[0058] Pulp may also be stiffened by the use of heat or caustic
treatments such as mercerization. Examples of these types of fibers
include NHB416 which is a chemically crosslinked southern softwood
pulp which enhances wet modulus, available from the Weyerhaeuser
Corporation of Tacoma, Wash., U.S.A. Other useful pulps are
debonded pulp (NF405) also from Weyerhaeuser. HPZ3 from Buckeye
Technologies, Inc of Memphis, Tenn., U.S.A., has a chemical
treatment that sets in a curl and twist, in addition to imparting
added dry and wet stiffness and resilience to the fiber. Another
suitable pulp is Buckeye HPF2 pulp and still another is IP
SUPERSOFT.RTM. from International Paper Corporation. Suitable rayon
fibers are 1.5 denier Merge 18453 fibers from Tencel Incorporated
of Axis, Ala., U.S.A.
[0059] Superabsorbent materials useful in forming the absorbent
structure 101 may be chosen based on chemical structure as well as
physical form. These include superabsorbent materials with low gel
strength, high gel strength, surface cross-linked superabsorbent
materials, uniformly cross-linked superabsorbent materials, or
superabsorbent materials with varied cross-link density throughout
the structure 101. The superabsorbent materials may be based on
chemistries that include poly(acrylic acid),
poly(iso-butylene-co-maleic anhydride), poly(ethylene oxide),
carboxy-methyl cellulose, poly(-vinyl pyrrollidone), and
poly(-vinyl alcohol). The superabsorbent materials may range in
swelling rate from slow to fast.
[0060] The superabsorbent materials of the absorbent structure 101
of the present invention are desirably particulate. However, the
superabsorbent materials may alternatively be in the form of foams,
macroporous or microporous particles or fibers, particles or fibers
with fibrous or particulate coatings or morphology. The
superabsorbent materials may be in various length and diameter
sizes and distributions and may also be in various degrees of
neutralization. Counter-ions are typically Li, Na, K, Ca.
[0061] An exemplary superabsorbent material is available from
Stockhausen, Inc of Greensboro, N.C., U.S.A. and is designated
FAVOR.RTM. SXM 880. Another examplary superabsorbent material may
be obtained from the Dow Chemical Company of Midland, Mich., U.S.A.
under the name DRYTECH.RTM. 2035. A suitable fibrous superabsorbent
material is available from Camelot Technologies, Ltd., of High
River, Alberta, Canada and is designated FIBERDRI.RTM. 1241.
Another suitable superabsorbent material is available from Chemtall
Inc. of Riceboro, Ga., and is designated FLOSORB 60 LADY.RTM., also
known as LADYSORB 60.RTM..
[0062] The binder fibers are desirably activatable, such as upon
being heated, to form inter-fiber bonds within the absorbent
structure. As used herein, the inter-fiber bonds may be between the
binder fibers and the absorbent fibers, between the binder fibers
and the superabsorbent material, and/or among the binder fibers
themselves.
[0063] In one embodiment, the binder fibers are bicomponent, or
multicomponent binder fibers. As used herein, multicomponent fibers
refers to fibers formed from two (e.g., bicomponent) or more
polymers extruded from separate extruders but joined together to
form a single fiber. The polymers are arranged in substantially
constantly positioned distinct zones across a cross-section of the
multi-component fibers and extend continuously along at least a
portion of, and more desirably the entire, length of the fiber. The
configuration of the multi-component fibers may be, for example, a
sheath/core arrangement in which one polymer is surrounded by
another, a side-by-side arrangement, a pie arrangement, an
"islands-in the-sea" arrangement or other suitable arrangement.
Bicomponent fibers are disclosed in U.S. Pat. No. 5,108,820 to
Kaneko et al., U.S. Pat. No. 4,795,668 to Krueger et al., U.S. Pat.
No. 5,540,992 to Marcher et al. and U.S. Pat. No. 5,336,552 to
Strack et al. Bicomponent fibers are also taught in U.S. Pat. No.
5,382,400 to Pike et al. and may be used to produce crimp in the
fibers by using the differential rates of expansion and contraction
of the two (or more) polymers.
[0064] Multicomponent binder fibers as used herein refers to
multicomponent fibers in which at least one of the binder fiber
components has a melt temperature that is less than at least one
other binder fiber component. For example, the binder fiber may be
a bicomponent fiber having a sheath/core arrangement in which the
sheath component of the binder has a melt temperature that is lower
than the melt temperature of the core component of the binder
fiber. Upon heating of the binder fiber, the component having the
lower melt temperature can fuse and bond to nearby absorbent
fibers, superabsorbent material or other binder fibers while the
other component, or components, remain in a generally unmelted
state so as to generally maintain the integrity of the binder
fiber.
[0065] In other embodiments, the binder fibers can be monofilament
or homofilament fibers, biconstituent fibers and the like, as well
as combinations thereof.
[0066] The binder fibers are desirably constructed of a material,
or material, that are readily heated upon exposure to an activation
energy, and more particularly the binder fibers are desirably
susceptible to dielectric heating via exposure to electromagnetic
energy wherein the binder fibers are melted to facilitate forming
inter-fiber bonds within the absorbent structure.
[0067] Dielectric heating is the term applied to the generation of
heat in non-conducting materials by their losses when subject to an
alternating electric field of high frequency. For example, the
frequency of the electric field desirably ranges from about 0.01 to
about 300 GHz (billion cycles/sec). Heating of non-conductors by
this method is extremely rapid. This form of heating is applied by
placing the non-conducting material between two electrodes, across
which the high-frequency voltage is applied. This arrangement in
effect constitutes an electric capacitor, with the load acting as
the dielectric. Although ideally a capacitor has no losses,
practical losses do occur, and sufficient heat is generated at high
frequencies to make this a practical form of heat source.
[0068] The frequency used in dielectric heating is a function of
the power desired and the size of the object being heated.
Practical values of voltages applied to the electrodes are 2000 to
5000 volts/in of thickness of the object. The source of power is by
electronic oscillators that are capable of generating the very high
frequencies desirable.
[0069] The basic requirement for dielectric heating is the
establishment of a high-frequency alternating electric field within
the material or object to be heated. Once the electric field has
been established, the second requirement involves dielectric loss
properties of the material to be heated. The dielectric loss of a
given material occurs as a result of electrical polarization
effects in the material itself and may be through dipolar molecular
rotation and ionic conduction. The higher the dielectric loss of a
material, the more receptive to the high frequency energy it
is.
[0070] In one embodiment, the electromagnetic energy is radio
frequency or RF radiation, which occurs at about 27 MHz and heats
by providing some portion of the total power delivered as ionic
conduction to the molecules within the workpiece, with much of the
remainder of the power delivered as dipolar molecular rotation.
[0071] In another embodiment, the electromagnetic energy is
microwave radiation, which is dielectric heating at still higher
frequencies. The predominate frequencies used in microwave heating
are 915 and 2450 MHz. Microwave heating is 10 to 100 times higher
in frequency than the usual dielectric heating, resulting in a
lower voltage requirement if the loss factor is constant, though
the loss factor is generally higher at microwave frequencies.
[0072] Microwave radiation can penetrate dielectric materials and
be absorbed uniformly, thereby generating heat uniformly. Microwave
energy is also selectively absorbed, offering a means for
self-limiting the energy taken up by heterogeneous materials,
making overheating less likely. These combined effects allow
microwave heating to be more rapid, with less heating of
surrounding materials, with a low thermal lag, and therefore with
good control.
[0073] It is understood that the binder fibers or other suitable
binding material may be activatable other than by dialectric
heating, such as by convective or infrared heating or other
non-thermal activation, as long as the binder fibers can be
incorporated into the absorbent structure 101 prior to activation
of the binder fibers to form inter-fiber bonds within the absorbent
structure and then subsequently activated to form such inter-fiber
bonds to thereby form the stabilized absorbent structure 101.
[0074] The binder fibers desirably have a fiber length which is at
least about 0.061 mm. The binder fiber length can alternatively be
at least about 3 mm and can optionally be at least about 6 mm. In a
further feature, the binder-fibers can have a length of up to about
30 mm or more. The binder fiber length can alternatively be up to
about 25 mm, and can optionally be up to about 19 mm. In a further
aspect, the absorbent structure 101 may include binder fibers
having lengths approximating one of the dimensions (e.g., length or
width) of the absorbent structure. A relatively long binder fiber
length provides an increased number of inter-fiber bond points upon
activation of the fibers to help generate improved integrity and
permeability of the absorbent structure 101.
[0075] Synthetic fibers suitable for use as binder fibers in the
absorbent structure 101 include those made from synthetic matrix
polymers like polyolefins, polyamides, polycaprolactones,
polyetheramides, polyurethanes, polyesters, poly (meth) acrylates
metal salts, polyether, poly(ethylene-vinyl acetate) random and
block copolymers, polyethylene-b-polyethylene glycol block
copolymers, polypropylene oxide-b-polyethylene oxide copolymers
(and blends thereof) and any other suitable synthetic fibers known
to those skilled in the art.
[0076] In one embodiment, an energy receptive additive can be
included in the binder fibers during production thereof wherein the
additive allows the binder fibers to reach their melting
temperature much more rapidly than without the additive. This
allows inter-fiber bonding in the absorbent structure 101 to occur
at a faster rate than without the additive. The additive is
desirably capable of absorbing energy at the frequency of
electromagnetic energy (e.g., between 0.01 GHz and 300 GHz)
rapidly, such as in the range of fractions of a second, desirably
less than a quarter of a second and at most about half a second.
However, it is contemplated that absorbent structures which involve
the absorption of energy and bonding of the binder fibers with the
absorbent fibers over a period as long as about 30 seconds are
intended to be within the scope of this invention. Melting of the
binder fibers will depend on a number of factors such as generator
power, additive receptivity, fiber denier, which is generally
between 1 and 20, and the composition of the matrix polymer of the
binder fiber.
[0077] The energy receptive additive may be added to a fiber-making
matrix polymer as it is compounded, or coated onto the binder fiber
after the fiber is produced. A typical method of compounding the
additive with the matrix polymer is with a twin screw extruder,
which thoroughly mixes the components prior to extruding them. Upon
extrusion, the polymer blend is usually pelletized for convenient
storage and transportation.
[0078] If the binder fiber is a bicomponent fiber, the energy
receptive additive may be added to either or both of the fiber
components. The energy receptive additive may also be added to one
or more components, preferably the continuous phase, of a
biconstituent fiber, and intermittently distributed throughout the
length and cross-section of the fiber. If the additive to be used
is not compatible with the matrix polymer into which it is to be
blended, a "compatibilizer" may be added to enhance the blending.
Such compatibilizers are known in the art and examples may be found
in U.S. Pat. Nos. 5,108,827 and 5,294,482 to Gessner.
[0079] The energy receptive additives can be receptive to various
specific spectra of energy. Just as a black item will absorb more
energy and become warmer than the same item colored white when
subjected to the same amount of solar energy, energy receptive
additives will absorb energy at their specific wavelength, directed
at them.
[0080] A successful energy receptive additive should have a
dielectric loss factor, as discussed previously, which is
relatively high. The energy receptive additives useful in this
invention typically can have a dielectric loss factor measured in
the RF or microwave frequency of between about 0.5 and 15, more
particularly between about 1 and 15, and still more particularly
between about 5 and 15. It should be noted that the dielectric loss
factor is a dimensionless number. It is preferred that the fiber
have a dielectric loss tangent of between about 0.1 and about 1,
and more particularly between about 0.3 and about 0.7.
[0081] The energy receptive additive may be, for example, carbon
black, magnetite, silicon carbide, calcium chloride, zircon,
alumina, magnesium oxide, and titanium dioxide. The energy
receptive additive may be present in an amount between 2 and 40
weight percent, and more particularly between 5 and 15 weight
percent. The binder fibers may be crimped, extendible and/or
elastic.
[0082] Synthetic fibers incorporating such energy receptive
additives are discussed at greater length in co-assigned U.S.
patent application Ser. No. 10/034,079 filed Dec. 20, 2001 and
entitled Targeted Bonding Fibers for Stabilized Absorbent
Structures, the entire disclosure of which is incorporated herein
by reference. Absorbent structures incorporating binder fibers
having such energy receptive additives are discussed in co-assigned
U.S. patent application Ser. No. 10/033,860 filed Dec. 20, 2001 and
entitled Targeted On-Line Stabilized Absorbent Structures.
[0083] In addition to the binder fibers having an energy receptive
additive, or as an alternative thereto, the binder fibers (or at
least one binder fiber component thereof where the binder fiber is
a multicomponent fiber) may be constructed to have a relatively low
melting temperature, such as less than about 200.degree. C., more
desirably less than about 150.degree. C., even more desirably less
than about 110.degree. C., still more desirably less than about
90.degree. C., and most desirably less than about 80.degree. C. In
such an instance, the absorbent fibers and superabsorbent material
of the absorbent structure 101 can act as a source of heat to
indirectly transfer energy to melt the low melting temperature
binder fibers. The absorbent fibers thus act as an energy receptive
material, and are excited to melt the adjacent low melting
temperature polymers of the binder fibers for bonding to the
absorbent fibers, to the superabsorbent material and/or to each
other. This melting will depend on a number of factors such as
generator power, moisture content, specific heat, density of the
absorbent structure 101 materials, fiber denier, which is generally
between 1 and 20, and the composition and concentration of the low
melting temperature polymers of the binder fibers.
[0084] The low melting temperature binder fibers desirably have a
low specific heat to allow rapid heating and cooling of the
absorbent structure 101. The low specific heat is useful during the
heating cycle since the heat absorbed by the binder fiber before
melting is relatively low. The low specific heat is also useful
during subsequent cooling of the absorbent structure 101, since the
heat to be removed from the binder fiber material to cause it to
solidify and stabilize the absorbent structure will be lower. A
suitable specific heat range of the binder fiber is in the range of
about 0.1 to about 0.6 calories/gram.
[0085] The binder fibers also desirably have a high thermal
conductivity to enable rapid transfer of heat therethrough. Thermal
conductivity is proportional to density and heat capacity/specific
heat capacity of the binder fiber material. It is beneficial to
achieve higher thermal conductivity using fibers with relatively
high density. For example, the binder fibers desirably have a
density of more than about 0.94 grams/cubic centimeter (g/cc). This
is helpful in accelerating the heating and cooling cycles during
activation of the binder fibers to stabilize the absorbent
structure 101. It is preferred that the thermal conductivity of the
binder fibers be greater than about 0.1
joules-sec.sup.-1-mole.sup.-1-degree Kelvin.sup.-1.
[0086] Materials having a low melting enthalpy are also desirable
for use as the binder fibers. The low melting enthalpy reduces the
energy requirement for transformation of the binder fiber from a
solid to a molten state during heating thereof and from the molten
state back to a solid state during subsequent cooling. As an
example, the melting enthalpy of the binder fibers is desirably
less than about 100 joules/gram, more particularly less than about
75 joules/gm and still more particularly less than about 60
joules/gm.
[0087] The binder fibers also desirably have a low melt viscosity
after activation, i.e., once the fiber is transformed from its
solid to its generally molten state. This enables the binder fiber
material to flow to the junction points between the binder fibers
and the absorbent fibers, superabsorbent material and/or other
binder fibers for forming stable inter-fiber bonds. As an example,
it is desired that the melt viscosity of the binder fibers be less
than about 100,000 centipoise, more particularly less than about
20,000 centipoise and most particularly less than about 10,000
centipoise.
[0088] The binder fibers also desirably have adequate surface
energy to be wettable by fluid to be absorbed by the absorbent
structure 101. This wettability is not required in all
applications, however, and may be accomplished using various
surfactants known to those skilled in the art if the binder fiber
is not intrinsically wettable.
[0089] Suitable binder fibers having a low melting temperature may
be made from polyethylene-polyvinyl alcohol (PE-PVA) block or
random copolymers, polyethylene-polyethylene oxide (PE-PEO)
block/graft copolymers, polypropylene-polyethylene oxide (PPPEO)
block/graft copolymers, polyester, polycaprolactone, polyamide,
polyacrylates, polyurethane (ester or ether based). The melting
point can be adjusted by adjusting the content of VA or PEO (for
those polymers with VA and PEO) or the configuration. The binder
fiber material can be made by compounding with a twin extruder,
Sigma mixer or other compounding equipment and then made into
fibers by conventional non-woven processes like meltblowing and
spunbonding.
[0090] As an example, absorbent structures incorporating such low
melting temperature binder fibers are discussed in co-assigned U.S.
application Ser. No. 10/034,021, filed Dec. 20, 2002 and entitled
Absorbent Structures Having Low Melting Fibers, the entire
disclosure of which is incorporated herein by reference.
[0091] A number of other polymers and sensitizers may also, or may
alternatively, be used with the energy receptive additives in
making the binder fibers. Specifically selecting and/or positioning
moieties along the polymer chain can affect the dielectric loss
factor of the polymer and enhance the responsiveness of the polymer
to electromagnetic energy. These include polymer composites from
blend, block, graft, random copolymers, ionic polymers and
copolymers and metal salts. Desirably, the presence of one or more
moieties along the polymer chain causes one or more of the
following: (1) an increase in the dipole moments of the polymer;
and (2) an increase in the unbalanced charges of the polymer
molecular structure. Suitable moieties include, but are not limited
to, aldehyde, ester, carboxylic acid, sulfonamide and thiocyanate
groups.
[0092] The selected moieties may be covalently bonded or ionically
attached to the polymer chain. As discussed above, moieties
containing functional groups having high dipole moments are desired
along the polymer chain. Suitable moieties include, but are not
limited to, urea, sulfone, amide, nitro, nitrile, isocyanate,
alcohol, glycol and ketone groups. Other suitable moieties include
moieties containing ionic groups including, but are not limited to,
sodium, zinc, and potassium ions.
[0093] For example, a nitro group may be attached to an aryl group
within the polymer chain. It should be noted that the nitro group
may be attached at the meta or para position of the aryl group.
Further, it should be noted that other groups may be attached at
the meta or para position of the aryl group in place of the nitro
group. Suitable groups include, but are not limited to, nitrile
groups. In addition to these modifications, one could incorporate
other monomer units into the polymer to further enhance the
responsiveness of the resulting polymer. For example, monomer units
containing urea and/or amide groups may be incorporated into the
polymer.
[0094] Suitable moieties include aldehyde, ester, carboxylic acid,
sulfonamide and thiocyanate groups. However, other groups having or
enhancing unbalanced charges in a molecular structure can also be
useful; or a moiety having an ionic or conductive group such as,
e.g., sodium, zinc, and potassium ions. Other ionic or conductive
groups may also be used.
[0095] Specific combinations include low density
PE/polyethylene-polyvinyl- acetate block copolymer,
LDPE/polyethylene glycol, PE/polyacrylates, polyethylene-vinyl
acetate copolymer, polyester, polyurethane, polyacrylates,
polyethylene glycol (PEG), polyacrylamide (PAA), polyethylenimine
(PEEM), polyvinyl acetate (PVAC), polyvinyl alcohol (PVA),
polymethylacylic acidsodium salt (PMA-Na), polyacylic acid sodium
salt (PA-Na), and poly (styrene solfonate-co-methyl acylic acid)
sodium salt (P (SS-co-MA)-Na), and polymers of terephthalic acid,
adipic acid and 1,4 butanediol, and polybutylene succinate
copolymers. Other materials include polymers of terephtalic acid,
adipic acid and 1,4-butanediol, sold by BASF Corporation under the
name ECOFLEX.RTM. or by Eastman Chemical Co. under the name Eastar
Bio.TM. copolyester. Blends and grafted copolymers of the above
listed polymers are also suitable.
[0096] The absorbent structure 101 of the present invention is
desirably of unitary construction. As used herein, the unitary
construction of the absorbent structure 101 means that the
absorbent structure is a single non-woven web or layer comprising a
mixture of absorbent fibers, binder fibers and, optionally,
superabsorbent material. In the illustrated embodiment of FIGS.
1-4, a single absorbent structure 101 comprises substantially the
entire absorbent body 53 of the diaper 21 (i.e., the dimensions of
the absorbent structure substantially define the dimensions of the
absorbent body). However, it is contemplated that the absorbent
body 53 may comprise more than one layer, wherein at least one of
the layers is an absorbent structure 101 of the present invention,
and remain within the scope of this invention as long as the
absorbent structure is itself of unitary construction.
[0097] As an example, in one embodiment the absorbent structure 101
is made by first forming or otherwise collecting the absorbent
fibers, superabsorbent material and binder fibers into a unitary
structure having a desired shape, contour and/or material
distribution prior to activation of the binder fibers (e.g., prior
to inter-fiber bonding within the absorbent structure) to define a
non-woven, generally pre-stabilized absorbent structure. The binder
fibers are subsequently activated to form inter-fiber bonds within
absorbent structure to thereby stabilize the absorbent
structure.
[0098] Optionally, a substantially hydrophilic tissue wrapsheet
(not illustrated) may be employed to help maintain the integrity of
the absorbent structure 101, or the entire absorbent body 53. The
tissue wrapsheet is typically placed about the absorbent structure
or the absorbent body over at least the two major facing surfaces
thereof and is composed of an absorbent cellulosic material, such
as creped wadding or a high wet-strength tissue. The tissue
wrapsheet can also be configured to provide a wicking layer that
helps to rapidly distribute liquid to the absorbent fibers within
the absorbent body 53. The wrapsheet material on one side of the
absorbent body may be bonded to the wrapsheet located on the
opposite side of the fibrous mass to effectively entrap the
absorbent body.
[0099] In one embodiment, the material composition of the
pre-stabilized absorbent structure 101 (e.g., prior to activation
of the binder fibers) may be from about 0.1 to about 60 weight
percent binder fiber, from about 0 to about 80 weight percent
superabsorbent material, and from about 5 to about 98 weight
percent absorbent fibers. More particular embodiments may have from
about 2 to about 10 weight percent binder fiber, from about 30 to
about 70 weight percent superabsorbent material and from about 30
to about 70 weight percent absorbent fiber. In other embodiments,
the pre-stabilized absorbent structure may have from about 0.1 to
about 5 weight percent binder fiber.
[0100] In another embodiment, the pre-stabilized absorbent
structure 101 can include an amount of binder fibers which is at
least about 0.1 weight percent with respect to the total weight of
the absorbent structure. The amount of binder fibers can
alternatively be at least about 1 weight percent, and can
optionally be at least about 3 weight percent. In other aspects,
the amount of binder fibers can be up to a maximum of about 30
weight percent, or more. The amount of binder fibers can
alternatively be up to about 20 weight percent, and can optionally
be up to about 5 weight percent.
[0101] The absorbent fibers, binder fibers and superabsorbent
material are desirably distributed within the absorbent structure
generally across the full width of the absorbent structure, along
the full length thereof and throughout the thickness thereof.
However, the concentration of absorbent fibers, binder fibers
and/or superabsorbent material within the absorbent structure 101
may be non-uniform i) across the width of the absorbent structure,
ii) along the length of the absorbent structure, and/or iii) along
the thickness or z-direction 127 of the absorbent structure. For
example, a heavier concentration of absorbent fibers, binder fibers
and/or superabsorbent material may be disposed in different strata
(e.g., in the z-direction) or in different regions (e.g., along the
length or across the width) of the absorbent structure.
[0102] It is also contemplated that one or more strata or regions
of the absorbent structure 101 may be devoid of binder fibers
and/or superabsorbent material, as long as the absorbent structure
is of unitary construction and includes binder fibers in at least a
portion of the structure. It is further contemplated that binder
fibers constructed of different materials may be disposed in
different strata or regions of the absorbent structure 101 without
departing from the scope of this invention.
[0103] The average basis weight of the pre-stabilized absorbent
structure 101 is desirably in the range of about 30 to about 2500
grams/square meter (gsm), more desirably within the range of about
50 to about 2000 gsm, and even more desirably within the range of
about 100 to about 1500 gsm. The pre-stabilized absorbent structure
101 can also be formed to have a non-uniform basis weight across
its width or along its length, with one or more high basis weight
regions, and one or more low basis weight regions. In at least one
high basis weight region, at least a significant portion of the
absorbent structure 101 can have a composite basis weight which is
at least about 700 gsm. The high basis weight region can
alternatively have a basis weight of at least about 750 gsm, and
can optionally have a basis weight of at least about 800 gsm. In
other aspects, the high basis weight region of the absorbent
structure 101 can have a composite basis weight of up to about 2500
gsm or more. The high basis weight region can alternatively have a
basis weight of less than or equal to about 2000 gsm, and more
particularly less than or equal to about 1500 gsm.
[0104] Additionally, in at least one low basis weight region, the
pre-stabilized absorbent structure 101 can have a composite basis
weight of at least about 50 gsm. The low basis weight region can
alternatively have a basis weight of at least about 100 gsm, and
can optionally have a basis weight of at least about 150 gsm. In
another alternative configuration, the low basis weight region of
the absorbent structure 101 can have a composite basis weight of up
to about 700 gsm, or more. The low basis weight region can
alternatively have a basis weight of up to about 600 gsm, and can
optionally have a basis weight of up to about 500 gsm.
[0105] In another aspect of the present invention, the absorbent
structure 101 formed prior to activation of the binder fibers may
have a density which is at least a minimum of about 0.01 g/cc as
determined at a restraining pressure of 1.38 KPa (0.2 psi). The
density can alternatively be at least about 0.02 g/cc, and can
optionally be at least about 0.03 g/cc. In other aspects, the
density may be up to a maximum of about 0.12 g/cc, or more. The
density can alternatively be up to about 0.11 g/cc, and can
optionally be up to about 0.1 g/cc. In one embodiment, the density
of the pre-stabilized absorbent structure is substantially uniform
throughout the absorbent structure. In another embodiment, the
density is non-uniform across the width of the absorbent structure
and/or along the length of the absorbent structure.
[0106] As used throughout the present application, the term
"non-uniform" as used in reference to a particular characteristic
or feature of the absorbent structure, is intended to mean that the
characteristic or feature is non-constant or otherwise varies
within the absorbent structure in accordance with a predetermined
non-uniformity, e.g., an intended non-uniformity that is greater
than non-uniformities resulting from normal processing and
tolerance variations inherent in making absorbent structures. The
non-uniformity may be present as a either a gradual gradient or as
a stepped gradient, such as where the concentration, basis weight
and/or density changes abruptly from one strata or region to an
adjacent strata or region within the absorbent structure, and may
occur repeatedly within the absorbent structure or may be limited
to a particular portion of the absorbent structure.
[0107] The pre-stabilized absorbent structure 101 may also be
formed to have a thickness which is non-uniform along the length of
the absorbent structure and/or across the width of the absorbent
structure. The thickness is the distance between the major faces
the absorbent structure, as determined in a local z-direction of
the absorbent structure directed perpendicular to the planes of the
major faces thereof at the location at which the thickness is
determined. A variation in thickness may be present as a gradual or
otherwise sloped change in thickness or as a stepped change in
thickness whereby the thickness changes abruptly from one portion
of the absorbent structure to an adjacent portion.
[0108] Accordingly, one or more portions of the absorbent structure
101 can have a relatively lower thickness, and other portions of
the absorbent structure can have a relatively higher thickness. For
example, in the illustrated embodiment, a portion 103 (FIGS. 2 and
4) of the absorbent structure 101 which forms the absorbent body 53
of the diaper 21 is substantially thicker than the rest of the
absorbent structure and corresponds generally to the front region
25 of the diaper to provide a targeted area of increased absorption
capacity. The thicker portion 103 of the absorbent structure 101
extends lengthwise less than the full length of the absorbent
structure and is spaced longitudinally inward of the longitudinal
ends of the structure. As shown in FIG. 2 the thicker portion 103
is also centrally positioned between the side edges 105 of the
absorbent structure and spaced laterally inward from the side edges
thereof.
[0109] Additionally, or alternatively, the pre-stabilized absorbent
structure 101 may be formed to have a non-uniform width along the
length of the absorbent structure. The width is the distance
between the side edges of the absorbent structure, as determined in
a direction parallel to the Y-axis of the absorbent structure. A
variation in width may be present as a gradual or otherwise sloped
change in width or as a stepped change in which the width changes
abruptly from one portion of the absorbent structure to an adjacent
portion. As an example, the absorbent structure 101 may have any of
a number of shapes, including rectangular, I-shaped, or T-shaped
and is desirably narrower in the crotch region 27 than in the front
or back regions 25, 29 of the diaper 21. As illustrated in phantom
in FIG. 1, the shape of the absorbent body 53 is defined by the
absorbent structure 101 and is generally T-shaped, with the
laterally extending crossbar of the "T" generally corresponding to
the front region 25 of the diaper 21 for improved performance,
especially for male infants.
[0110] It is understood, however, that the pre-stabilized absorbent
structure 101 may have a substantially uniform thickness and/or may
have a substantially uniform width, i.e., the side edges 105 of the
absorbent structure are substantially straight and in generally
parallel relationship with each other along the length of the
absorbent structure.
[0111] The absorbent structure 101 is formed in accordance with a
desired method for making such an absorbent structure whereby the
absorbent fibers, superabsorbent material and binder fibers are
collected on a forming surface while the binder fibers are in a
pre-activated condition. The absorbent structure 101 is thus formed
as a unitary structure having a desired shape and contour (e.g., a
desired length, width and/or thickness profile) before activation
of the binder fibers occurs, i.e., before inter-fiber bonding
occurs within the absorbent structure. The distribution of fibers
and superabsorbent material within the pre-stabilized absorbent
structure 101 may also be controlled during formation thereof so
that the concentration of materials, basis weight and/or density is
substantially non-uniform prior to activation of the binder fibers.
The orientation of the absorbent fibers and binder fibers within
the absorbent structure is desirably generally random following
formation of the pre-stabilized absorbent structure, including at
the major faces, side edges and longitudinal ends of the absorbent
structure.
[0112] The binder fibers are then activated to form inter-fiber
bonds with the absorbent fibers, the superabsorbent material and/or
other binder fibers to stabilize the absorbent structure 101. More
particularly, in one embodiment the pre-stabilized absorbent
structure 101 is exposed to high-frequency electromagnetic energy
(e.g., microwave radiation, radio frequency radiation, etc.) to
melt the binder fibers for inter-fiber bonding with the absorbent
fibers, and then cooled to generally solidify the binder fibers to
thereby secure the inter-fiber bonds between the binder fibers and
the absorbent fibers.
[0113] The absorbent structure desirably remains unmolded during
and after activation of the binder fibers. As used herein, the term
unmolded during and after activation of the binder fibers means
that the binder fibers are not subjected to an operation in which
the shape and/or orientation thereof within the absorbent
structure, and particularly at the major faces, side edges and
longitudinal ends of the absorbent structure, is changed as a
result of pressure being applied to the binder fibers while the
binder fibers are heated to a generally molten or otherwise
activated state. For example, in typical molding operations, the
absorbent structure or at least one or both major faces of the
absorbent structure is pressed against or within a mold during or
after heating of the binder fibers, or the mold itself may be
heated so as to heat the binder fibers. Such a molding process
forces a reorientation of the absorbent structure fibers to a
generally non-random orientation and, and may also re-shape or even
emboss the major surfaces of the absorbent structure. Because the
absorbent structure 101 remains unmolded during and after
activation of the binder fibers, the orientation of fibers within
the absorbent structure, including at the major faces, side edges
and longitudinal ends thereof, remains generally random during and
after activation of the binder fibers to stabilize the absorbent
structure.
[0114] Following stabilization of the absorbent structure 101, the
structure may have substantially the same shape, contour, material
distribution and other characteristics as the pre-stabilized
absorbent structure. The stabilized absorbent structure 101 is
desirably sufficiently strong to support a peak tensile load which
is at least a minimum of about 100 grams per inch (g/inch) of
cross-directional (Y-axis) width of the absorbent structure. The
stabilized absorbent structure 101 strength can alternatively be at
least about 200 g/inch, and can optionally be at least about 500
g/inch. In other aspects, the absorbent structure 101 strength can
be up to a maximum of about 10,000 g/inch, or more. The strength
can alternatively be up to about 5000 g/inch, and can optionally be
up to about 2000 g/inch. In determining the strength of the
stabilized absorbent structure 101, any previously formed,
separately provided reinforcing component should be excluded from
the determination. Such reinforcing components (not shown) may, for
example, be provided by a scrim, a continuous filament fiber, a
yarn, an elastic filament, a tissue, a woven fabric, a nonwoven
fabric, an elastic film, a polymer film, a reinforcing substrate,
or the like, as well as combinations thereof.
[0115] The stabilized absorbent structure 101 can be configured to
have a strength sufficient to support a peak tensile load which is
significantly greater than the peak tensile load that can be
supported by the absorbent structure prior to activation of the
binder fibers. In a particular aspect, the absorbent structure 101
can be configured to have sufficient strength to support a peak
tensile load which is at least about 100% greater than the peak
tensile load that can be supported by the absorbent structure prior
to activation of the binder fibers. The stabilized structure 101
can alternatively be configured to support a peak tensile load
which is at least about 200% greater. Optionally, the stabilized
structure 101 can be configured to support a peak tensile load
which is at least about 300% greater. The percentage of increase in
the supported peak-load can be determined by the formula:
100*(F2-F1)/F1;
[0116] where:
[0117] F1=the peak tensile load that can be supported by the
absorbent structure 101 prior to activation of the binder fibers;
and
[0118] F2=the peak tensile load that can be supported by the
stabilized absorbent structure.
[0119] The peak load that can be supported by an absorbent
structure 101 can be determined by employing TAPPI Test Method
Number T 494 om-96 entitled "Tensile Properties of Paper and
Paperboard" (using constant rate of elongation apparatus) dated
1996. The test sample has a width of 1 inch (2.54 cm), and a length
of 6 inch (15.24 cm). The jaws used were INSTRON part number
2712-001 (available from Sintech, Inc., a business having offices
in Research Triangle Park, N.C., U.S.A.), and were arranged with an
initial separation distance of 5 inch (12.7 cm). The cross-head
speed was 12.7 mm/min, and the testing employed a MTS Systems Corp.
model RT/1 testing machine controlled by TESTWORKS version 4.0
software, which are available from MTS Systems Corp., a business
having office in Eden Prairie, Minn., USA. Substantially equivalent
equipment may optionally be employed.
[0120] The fluid permeability of the absorbent structure 101 is
also affected by the incorporation of binder fibers therein to
stabilize the absorbent structure. The fluid permeability is
defined by Darcy's Law and is measured for an absorbent saturated
with a particular amount of fluid. More particularly, the
permeability as that term is used herein is determined by the
following permeability test.
Permeability Test
[0121] A suitable permeability test apparatus is shown in FIGS. 15
and 16. The test apparatus comprises a cylinder 1134 and piston,
generally indicated at 1136. The piston 1136 comprises a
cylindrical LEXAN shaft 1138 having a concentric cylindrical hole
1140 bored down the longitudinal axis of the shaft. Both ends of
the shaft 1138 are machined to provide ends 1142, 1146. A weight,
indicated as 1148, rests on one end 1142 and has a cylindrical hole
1148a bored through at least a portion of its center. A circular
piston head 1150 is positioned on the other end 1146 and is
provided with a concentric inner ring of seven holes 1160, each
having a diameter of about 0.95 cm, and a concentric outer ring of
fourteen holes 1154, also each having a diameter of about 0.95 cm.
The holes 1154, 1160 are bored from the top to the bottom of the
piston head 1150. The piston head 1150 also has a cylindrical hole
1162 bored in the center thereof to receive end 1146 of the shaft
1138. The bottom of the piston head 1150 may also be covered with a
biaxially stretched stainless steel screen 1164 with square
openings of about 149 microns. A representative material for this
piston is part number 85385T972 from McMaster-Carr Supply, a
company having offices in Chicago, Ill., U.S.A.
[0122] Attached to the bottom end of the cylinder 1134 is a
stainless steel cloth screen 1166 that is biaxially stretched to
tautness prior to attachment. The screen 1166 has square openings
of about 105 microns. A representative material for the screen is
part number 85385T976 from McMaster-Carr Supply, a company having
offices in Chicago, Ill., U.S.A. A sample of the composite
indicated as 1168 is supported on screen 1166.
[0123] The cylinder 1134 is either bored from a transparent LEXAN
rod or equivalent or cut from a LEXAN tubing or equivalent and has
an inner diameter of about 6.00 cm and a height of approximately 10
cm. The cylinder includes a set of drainage holes (not shown) or
other suitable means for holding a fluid level in the cylinder at
approximately 7.8 cm above the screen 1166. Piston head 1150 is
machined from a LEXAN rod or equivalent. It has a height of
approximately 16 mm and a diameter sized such that it fits within
the cylinder 1134 with minimum wall clearance but still slides
freely. Hole 1162 in the center of the piston head 1150 is used to
match and provide snug, fluid impervious attachment to shaft end
1146. Shaft 1138 is machined from a LEXAN rod or equivalent and has
an outer diameter of about 2.32 cm and an inner diameter of about
0.64 cm. End 1146 is approximately 2.54 cm long and approximately
1.52 cm in diameter, forming an annular shoulder to support the
weight 1148. The annular weight 1148 has an inner diameter of about
1.59 cm so that it slips onto end 1142 of the shaft 1138 and rests
on the annular shoulder formed therein. The annular weight can be
made from a stainless steel or form other materials with corrosion
resistance to 0.9% isotonic saline solution. The combined weight of
the piston 1136 and weight 1148 equals approximately 596 g, which
correspond to a pressure of about 20.7 dynes/cm.sup.2) on an area
of 28.27 cm.sup.2.
[0124] When solutions flow through the piston/cylinder apparatus,
the cylinder 1134 generally rests on a 16 mesh rigid stainless
steel support screen (not shown). Alternatively, the
piston/cylinder arrangement may rest on a support ring (not shown)
which matches the walls of the cylinder but effectively does not
restrict flow from the bottom of the cylinder.
[0125] The piston and weight are placed in an empty cylinder to
obtain a measurement from the bottom of the weight to the top of
the cylinder. This measurement is taken using a caliper readable to
0.01 mm. Alternatively, this measurement is taken using a bulk
gauge with 0.01 mm accuracy such as a Model IDF1050E gauge
available from Mitutoyo America Corporation, a company having
offices in Aurora, Ill., U.S.A. This measurement will later be used
to calculate the height of the gel bed. It is important to measure
each cylinder empty and to keep track of which piston and weight
used. The same piston and weight should be used for measurement
when the absorbent structure sample is swollen.
[0126] The absorbent structure sample used for determining
permeability is formed by swelling a circular sample (e.g., a
cutout) of approximately 60 mm diameter placed in the bottom of the
permeability cup apparatus (the sample should be in contact with
the screen) with 0.9% (w/v) aqueous NaCl for a time period of about
60 minutes. The saline would be placed in a tray. A coarse plastic
or rubber mesh with uniform square openings of approximately 2-15
mm is used to allow saline to reach the cups to swell the
samples.
[0127] At the end of this period, the piston and weight are placed
on the swollen sample in the cylinder and then the cylinder,
piston, weight, and sample are removed intact from the saline. The
thickness of the swollen sample is determined by measuring from the
bottom of the weight to the top of the cylinder with a micrometer.
Alternatively, this measurement is taken using a bulk gauge with
0.01 mm accuracy such as a Model IDF-1050E gauge available from
Mitutoyo America Corporation, a company having offices in Aurora,
Ill., U.S.A., provided that the zero point is unchanged from the
initial thickness test. The thickness value obtained from measuring
the empty cylinder, piston, and weight is subtracted from the value
of the thickness obtained after swelling the absorbent structure.
The resulting value is the height "H" of the swollen sample.
[0128] The absorbent structure permeability measurement is
initiated by adding the NaCl solution to cylinder 1134 with swollen
sample 1168, piston 1150, and weight 1148 inside. The 0.9% NaCl
solution is added to achieve and maintain a fluid height of about
7.8 cm above the bottom of the swollen absorbent structure sample.
The quantity of fluid passing through the swollen sample versus
time is measured gravimetrically. Data points are collected every
second for thirty seconds once the fluid level has been stabilized
to and maintained at about 7.8 cm in height. The flow rate Q
through the swollen sample 1168 is determined in units of gm/sec by
a linear least-square fit of fluid passing through the sample 1168
(in grams) versus time (in seconds).
[0129] Permeability in square microns is obtained by the following
equation:
K=[Q*H*Mu*10.sup.8]/[A*Rho*P]
[0130] where K=Permeability (square microns), Q=flow rate (g/sec),
H=height of swollen absorbent structure sample (cm), Mu=liquid
viscosity (poise), A,=cross-sectional area for liquid flow
(cm.sup.2), Rho=liquid density (g/cm.sup.3), and P=hydrostatic
pressure (dynes/cm.sup.2). The hydrostatic pressure is calculated
from
P=Rho*g*h
[0131] where Rho=liquid density (g/cm.sup.3), g=gravitational
acceleration, nominally 981 cm/sec.sup.2, and h=fluid height, e.g.,
7.8 cm for the permeability test apparatus described above.
[0132] In general, the higher the permeability of the absorbent
structure when saturated, the more open the structure is. As a
result, the absorbent structure can more easily take in additional
fluid and is therefore less likely to leak. Without binder
material, the permeability of a non-woven absorbent structure is
based solely on the characteristics of the absorbent fibers and
superabsorbent material and therefore has a relatively low fluid
permeability, such as less than 20 square microns. The integrity of
the absorbent structure 101, and more particularly the void volume
thereof, is increased by stabilizing the structure with binder
materials, and more particularly by multi-component binder fibers,
to substantially increase the permeability of the absorbent
structure. For example, following activation of the binder fibers,
the stabilized absorbent structure 101 desirably has a permeability
throughout the absorbent structure as measured by the above
permeability test of greater than 20 square microns, more desirably
greater than about 40 square microns, and even more desirably
greater than about 60 square microns.
[0133] It is understood that the permeability may be non-uniform
along at least one of the length and the width of the absorbent
structure 101, as long as the local permeability of the absorbent
structure is at least greater than 20 square microns. Without being
bound to theory, it is also believed that an over-concentration of
binder fibers within the stabilized absorbent structure can
negatively affect the permeability of the absorbent structure. To
facilitate increased permeability of the absorbent structure, the
binder fiber concentration within the absorbent structure is
desirably in the range of about 0.1 percent to about 10 percent,
and more desirably in the range of about 0.1 percent to about 5
percent, to facilitate increased permeability of the absorbent
structure.
[0134] By forming the absorbent structure 101 generally in its
final form prior to activation of the binder fibers, e.g., with the
desired length, width, thickness and/or basis weight profile, no
additional shaping, e.g., cutting, of the structure is required. As
a result, the side edges of the absorbent structure 101 remain
uncut after activation of the binder fibers, even where the width
of the absorbent structure is non-uniform. It is also contemplated
that the longitudinal ends of the absorbent structure 101 may be
uncut, such as where each absorbent structure is formed as a
discrete structure instead of from a continuous web which is
subsequently cut into discrete structures.
[0135] The side edges of prior art stabilized absorbent structures
that must be cut to a desired width profile typically have a
cross-sectional edge profile, or surface contour, which is
generally concave as shown in FIG. 11. Without being bound to a
particular theory, it is believed that the concave surface contour
results from the fibrous material at the side edge of the absorbent
structure being pinched during cutting of the side edges. In
contrast, the uncut side edges of the stabilized absorbent
structure 101 of the present invention desirably have a
cross-sectional edge profile, or surface contour, which is other
than concave, such as generally straight and more desirably convex.
For example, FIG. 12 is a cross-sectional edge profile of one uncut
side edge of the stabilized absorbent structure 101 in which the
surface contour of the side edge is convex.
[0136] FIGS. 13 and 14 respectively illustrate the difference in
fiber orientation between an uncut side edge of the absorbent
structure 101 and a cut side edge of the prior art absorbent
structure. As can be seen in FIG. 13, the orientation of the fibers
at the uncut side edge of the absorbent structure 101 is
substantially random over its entire surface contour. The
orientation of fibers at the cut side edge of the prior art
stabilized absorbent structure is disrupted, particularly at the
concave segment of the surface contour, and is therefore considered
to be non-random along the entire surface contour.
Experiment 1--Edge Brightness Test
[0137] An experiment was conducted to quantify the difference
between the cross-sectional profile of the side edges of a
conventional stabilized absorbent structure wherein the side edges
have been cut, such as to form a desired width profile, and the
cross-sectional profile of the uncut side edges of a stabilized
absorbent structure 101 formed in accordance with the present
invention. A first set of five samples corresponded to a
conventional stabilized absorbent structure in which the side edges
were cut. Each of the test samples had a basis weight of about 350
gsm and a thickness of about 0.25 inches (about 8 mm) approximately
0.5 inches (e.g., about 12 mm) in from the side edge of the
absorbent structure. A second set of five samples corresponded to a
stabilized absorbent structure formed in accordance with the
present invention, and more particularly in accordance with the
absorbent structure 101 shown in FIG. 10, having a central region
of increased thickness intermediate the side edges and longitudinal
ends of the absorbent structure. These test samples each had a
basis weight of about 350 gsm and a thickness of about 0.25 inches
(about 8 mm) approximately 0.5 inches (e.g., about 12 mm) in from
the side edge of the absorbent structure.
[0138] Each test sample was placed on a piece of flat, black
construction paper measuring about 18.times.24 inches and
illuminated with an 8-bulb octagonal incident ring light to provide
incident omni-directional dark-field illumination. The sample and
background construction paper were aligned vertically under a lens
of a suitable image analysis system, such as that available from
Cambridge/Leica of Bannockburn, Ill., U.S.A. under the tradename
Quantimet 970 Image Analysis System, so that the sample filled
about one half (the right half) of the monitor screen of the image
system. Image formation was accomplished using a 50 mm EL-Nikkor
lens, f/2.8, with EL-to-F and F-to-C adapters, available from Nikon
OEM Sales of Melville, N.Y. The working distance between the lens
and the test sample was about 250 mm (about 10 inches). The total
field size (e.g., length) for 900 pixels was about 57 mm (about
2.25 inches).
[0139] An optical brightness profile at the side edge of the sample
was determined using the software routine of Appendix 1. More
particularly, sixty scanning frames were used to determine the
brightness of light imaged by the analysis system, with each frame
being about 0.59 mm in width. The arrangement was such that some of
the frames (e.g., about 25-30) imaged only the black construction
paper outward of the side edge of the sample and the remaining
frames imaged the side edge of the sample in a line extending
inward of the sample generally normal to the side edge in the X-Y
plane of the sample. The measured brightness was based on a 6-bit
gray scale, wherein 0 gray units equals black and 64 gray units
equals white. The white level was set at 0.75 volts so that the
maximum brightness encountered as an average within a frame would
be 90-96 percent of maximum gray scale.
[0140] A "transition" brightness, e.g., corresponding to the
outermost extent of the side edge within the set of scanning frames
was identified as the first non-zero brightness reading within the
scanning frames. Starting with the frame identified as the
transition brightness, the brightness reading from the next eleven
frames (marching inward from the side edge) was plotted (e.g.,
using Excel.RTM. software available from Microsoft) against the
logarithmic distance of each frame inward from and including the
starting frame. The data was then curve-fit with a second order
polynomial function to determine a coefficient "a" of the X.sup.2
term and a coefficient "b" of the X term of the function at a 95%
confidence range using a conventional student's T statistical
analysis based on N=11. The test was conducted at two side edge
locations of each sample.
[0141] For the first set of samples corresponding to the
conventional stabilized absorbent structure in which the side edges
were cut, the coefficient "a" of the X.sup.2 term of the second
order polynomial function used to curve fit the brightness data was
about -17.79 to about -28.81, with a mean of about -23.30. In
contrast, the coefficient "a" of the samples corresponding to the
stabilized absorbent structure of the present invention having
uncut side edges was in the range of about 6.37 to about 11.03 with
a mean of about 8.70. The coefficient "b" of the X term of the
second order polynomial function used to curve fit the brightness
data was in the range of about 45.90 to about 53.70 with a mean of
about 49.80 for the first set of samples and in the range of about
21.71 to about 26.69 with a mean of about 24.20 for the second set
of samples.
[0142] Accordingly, it is desired that the side edges of a
stabilized absorbent structure 101 constructed in accordance with
the present invention have an edge brightness profile defined by a
second order polynomial function, as determined by the edge
brightness test described above, in which the coefficient "a" of
the X.sup.2 term of the function is in the range of about -15 to
about 20 and the coefficient "b" of the X term of the function is
in the range of about 10 to about 40.
[0143] In particular embodiments, such as shown in FIG. 10, where
the thickness of the stabilized absorbent structure 101 is
non-uniform across its width and/or along its length there is a
defined thickness gradient intermediate the side edges and/or the
longitudinal ends of the absorbent structure. Using conventional
forming techniques, such an absorbent structure is formed of two
discrete layers (not shown) including a base layer and an upper
layer cut to a smaller width and/or length than the base layer and
adhered to the base layer intermediate the side edges and/or ends
of the base layer. By cutting the upper layer to the desired
narrower width, the conventional absorbent structure has a
relatively sharp thickness gradient across its width. However, by
forming a stabilized absorbent structure 101 of unitary
construction in accordance with the present invention, the
thickness gradient across the width of the absorbent structure is
substantially less than that of the conventional absorbent
structure.
Experiment 2--Absorbent Structure Brightness Test
[0144] An experiment was conducted to characterize the thickness
gradient of two different types of stabilized absorbent structures.
The first absorbent structure was a conventional stabilized
absorbent structure formed from two separate layers including a
base layer and an upper layer cut to a smaller width and length
than the base layer and adhered to the base layer intermediate the
side edges and longitudinal ends thereof. Three test samples
corresponding to this type of absorbent structure were used. The
second absorbent structure was a stabilized absorbent structure
formed in accordance with the present invention, and more
particularly in accordance with the absorbent structure 101 shown
in FIG. 10, having a central region of increased thickness
intermediate the side edges and longitudinal ends of the absorbent
structure. Three such test samples were used.
[0145] Each test sample was placed on a piece of flat, black
construction paper measuring about 18.times.24 inches and the
boundary of the sample was traced onto the construction paper with
a pencil. A central opening was then cut in construction paper by
cutting approximately 0.25 inches inside the boundary line and
removing the cut piece. The sample was then placed back on the
construction paper (e.g., on the boundary line) and then the sample
and construction paper were together placed on a conventional film
viewer, such as a Pickers/Marconi film viewer available from
Philips Medical Systems, N.A., of Bothell, Wash., U.S.A.
Fluorescent light was transmitted by the viewer through the sample
with the remaining light from the viewer blocked by the black
construction paper.
[0146] Light transmitted through the sample was imaged by a
suitable analysis system, such as that available from
Cambridge/Leica of Bannockburn, Ill., U.S.A. under the tradename
Quantimet 970 Image Analysis System to determine the intensity of
the light transmitted through the sample. The image formation was
accomplished using a 20 mm Nikon lens, f/4 with F-to-C adapter,
such as is available from Nikon OEM Sales of Melville, N.Y., U.S.A.
and with attached variable neutral density filter (e.g., "crossed
polars") to control light intensity reaching the scanner. The
working distance between the lens and the test sample was about 457
mm (e.g., about eighteen inches). The total field size used, for
900 pixels, was about 253 mm (almost ten inches) in width.
[0147] An optical brightness profile down the length of the sample
(e.g., the portion of the sample not blocked by the black
construction paper, including the region of increased thickness)
was determined using the software routine of Appendix 2. The tested
samples were measured in a direction corresponding to the
longitudinal axis of the corresponding absorbent structures from
which the samples were obtained. However, the samples could also be
tested in a direction corresponding to the cross-direction, or
lateral axis of the absorbent structures. The brightness of light
transmitted through the sample was determined at 60 frames down the
sample length, with each frame being about 3 mm in width. The
measured brightness is based on a 6-bit gray scale, wherein 0 gray
units equals black and 64 gray units equals white. The onset of a
brightness gradient (e.g., corresponding to a change in thickness
of the sample) down the length of the sample was determined by
multiplying a frame measurement by 1.1 (e.g., a ten percent
increase). If the adjacent frame measurement exceeds that value,
then a gradient has begun.
[0148] The brightness gradient, as determined with a 95% confidence
based on a conventional student's T statistical analysis, with N
equal to either 4 or 3, down the length of each sample was averaged
to determine the average gradient for each set of samples. For the
first set of samples corresponding to the conventional stabilized
absorbent structure in which a narrower upper layer is adhered to a
base layer, the average brightness gradient was in the range of
about 4.02 to about 6.84 gray units/mm, with a mean of about 5.43
gray units/mm. In contrast, the average brightness gradient of the
samples corresponding to the stabilized absorbent structure of the
present invention having a unitary construction was in the range of
about 0.93 to about 2.31 gray units/mm, with a mean of about 1.62
gray units/mm.
[0149] Accordingly, it is desired that the average brightness
gradient of a stabilized absorbent structure 101 constructed in
accordance with the present invention to have a non-uniform
thickness across its width is desirably in the range of about 0.5
to about 3.0 gray units/mm, and more desirably in the range of
about 0.93 to about 2.31 gray units/mm, as determined by the
absorbent structure brightness test. Where the thickness of the
absorbent structure is non-uniform along the length of the
absorbent structure, the average brightness gradient along the
length of the absorbent structure intermediate the longitudinal
ends thereof, as determined by the absorbent structure brightness
test, is also in the range of about 0.5 to about 3.0 gray units/mm,
and more desirably in the range of about 0.93 to about 2.31 gray
units/mm.
[0150] Where the binder fibers are activated by subjecting the
pre-stabilized absorbent structure 101 to dialectric heating (e.g.,
by exposure to electromagnetic energy), the stabilized absorbent
structure also has unique physical characteristics associated with
the presence of the binder fibers and subsequent activation by
electromagnetic energy. These characteristics may be qualified and
quantified using measurements of location and degree of oxidation
and bonding efficiency within the absorbent structure. More
particularly, techniques such as ultraviolet, visible, near
infrared, infrared and Raman spectroscopy; surface analysis;
differential scanning calorimetry; chromatographic separation; and
various microscopic techniques can demonstrate the unique
properties of materials heated "externally" via convection or
infrared radiant heat transfer, versus "internally" using
dielectric techniques.
[0151] With infrared and convection heating, radiant energy is
translated into heat at the outer surface of the absorbent
structure where the surface temperature rises rapidly. Heat at the
outer surface of the absorbent structure eventually diffuses via
thermal conduction toward the center of the absorbent structure.
This heating process is relatively slow and it takes a relatively
significant time for the center of the absorbent structure to reach
the threshold temperature necessary to melt binder fibers disposed
toward the center of the structure. The slow process of thermal
conduction is dependent upon the thermal conductivity of the
structure and its overall dimensions (e.g., thickness). For such a
heating process, a greater oxidation of fibers consequently occurs
toward, and more particularly on, the outer surface of the
structure. Thermal bonding in this manner also results in some
yellowing of the fibers at the outer surface of the absorbent
structure.
[0152] For dielectric heating (e.g., using electromagnetic energy),
the peak temperature of the absorbent structure 101 is also near
the outer surface. However, the temperature rise at the center of
the absorbent structure 101 is nearly identical to that at the
outer surface. This occurs since the dielectric heating process is
active and direct. This direct transfer of energy to the center of
the absorbent structure is less dependent upon thermal conductivity
and more dependent upon the dielectric field strength and
dielectric properties of the absorbent structure materials. In
other words, the heating occurs generally from the center of the
absorbent structure 101 out toward the outer surface thereof.
[0153] Infrared energy must be applied from about 3 to 30 times
longer than dielectric heating to achieve generally uniform heating
throughout the absorbent structure. More particularly, such an
extended heating time is required in order to attain a desired
temperature threshold (e.g., the melting temperature of the binder
fiber) at the center of the absorbent structure. When properly
applied, dielectric heating occurs rapidly and more uniformly. The
rapid and uniform direct heating prevents large-scale thermal
degradation of polymers within the heated absorbent structure.
[0154] The percent oxidation occurring for any given structure is
proportional to the time exposure of the polymer to air at an
elevated temperature (i.e., above 75.degree. C.). Infrared heating
maintains a higher surface temperature throughout the heating cycle
than microwave heating. The projected percent oxidation from
infrared and convection heating will be from 5 to 35 (or more)
times greater at the outer surface of an absorbent structure than
it would be at the outer surface of an structure subjected to
dielectric heating. Heating an absorbent structure by microwave
radiation will, therefore, produce a structure having less than 5
times more oxidation at its outer surface than at its center and
more particularly less than 3 times more oxidation at its outer
surface than at its center.
[0155] Large differences in oxidative degradation due to surface
heating are easily measured using the analytical techniques
previously described. For this application, typical compounds
resulting from oxidative degradation include the existence of
highly colored (high molar absorptivity) species. These colored
compounds result from the formation of identifiable unsaturation.
Examples include polyenes, unsaturated ketones, carboxyl-containing
organic chains, quinones, and in general compounds with conjugated
double bonds formed by the oxidation/degradation mechanisms of free
radical formation, elimination reactions, and random chain
scission. Often the increased oxidation can readily be observed
with the unaided eye, making the materials heated using infrared
and convection heating appear more yellow and thus of perceived
lower quality.
[0156] A rapid, non-destructive method to analyze polyolefins and
cellulosic materials for the presence of compounds resulting from
thermal degradation is hereafter described. The ultraviolet and
visible spectrum is measured on a control and heated sample. The
resulting spectra are subtracted and the difference spectra
compared to a series of reference sample spectra prepared by
heating a series of comparison samples at elevated temperatures for
different known periods to bracket the heating application. The
spectra yield direct information on the color and molecular
absorptive properties of the thermal degradation products present
in polymers and cellulose. The ratios of the absorbance maximum for
the ultraviolet versus the visible spectrum yields precise
information on the chemical species present and on the approximate
concentrations. This basic procedure can be reproduced using
ultraviolet and visible fluorescence, Raman spectroscopy, and
infrared spectroscopy for similar and complementary results.
[0157] For more detailed structural analysis, the polymer and
cellulosic materials can be dissolved in appropriate solvents,
subjected to liquid chromatographic separation, and further
analyzed using either the spectroscopic techniques described above
or by mass spectrometry to determine the structure and molecular
weight of any degradation compounds. These compounds are often
highly colored as yellow or brown due to the browning effect of
thermal degradation oxidation. There is a plethora of literature
describing the detailed analysis of degradation compounds in
synthetic and natural polymers and most of these techniques are
quite sufficient for measuring the relative amount of oxidation
throughout the cross-section of the heated structure. In addition,
the use of scanning electron microscopy with osmium tetroxide
staining will reveal the integrity of bond points within the
structure indicating the maximum heating temperature reached in any
portion of the heated structure during the process.
[0158] FIGS. 5-10 illustrate one embodiment of apparatus, generally
indicated at 121, for making a stabilized absorbent structure 101
in accordance with the present invention and the above-described
method. The apparatus 121 has an appointed lengthwise or
machine-direction 123, an appointed widthwise or cross-direction
125 which extends transverse to the machine direction, and an
appointed thickness or z-direction 127. For the purposes of the
present disclosure, the machine-direction 123 is the direction
along which a particular component or material is transported
lengthwise or longitudinally along and through a particular, local
position of the apparatus. The cross-direction 125 lies generally
within the plane of the material being transported through the
process, and is aligned perpendicular to the local
machine-direction 123. The z-direction 127 is aligned substantially
perpendicular to both the machine-direction 123 and the
cross-direction 125, and extends generally along a depth-wise,
thickness dimension. In the illustrated embodiment, the machine
direction 123 corresponds to the longitudinal X-axis of the diaper
21 of FIG. 1 and the cross-direction 125 corresponds to the lateral
Y-axis of the diaper.
[0159] The apparatus 121 comprises an airforming device, generally
indicated at 131 in FIGS. 5 and 6, having a movable, foraminous
forming surface 135 extending about the circumference of a drum 137
(the reference numerals designating their subjects generally). The
drum 137 is mounted on a shaft 139 (FIG. 7) connected by bearings
141 to a support 143. As shown in FIG. 7, the drum includes a
circular wall 145 connected to the shaft 139 for conjoint rotation
therewith. The shaft 139 is rotatably driven by a suitable motor or
line shaft (not shown) in a counter-clockwise direction in the
illustrated embodiment of FIGS. 5 and 6. The circular wall 145
cantilevers the forming surface 135 and the opposite side of the
drum 137 is open. A vacuum duct 147 located radially inward of the
forming surface 135 extends over an arc of the drum interior. The
vacuum duct 147 has an arcuate, elongate entrance opening 149 under
the foraminous forming surface 135, as will be described in more
detail hereinafter, for fluid communication between the vacuum duct
and the forming surface. The vacuum duct 147 is mounted on and in
fluid communication with a vacuum conduit 151 connected to a vacuum
source 153 (represented diagrammatically in FIG. 7). The vacuum
source 153 may be, for example, an exhaust fan.
[0160] The vacuum duct 147 is connected to the vacuum supply
conduit 151 along an outer peripheral surface of the conduit and
extends circumferentially of the conduit. The vacuum duct 147
projects radially out from the vacuum conduit 151 toward the
forming surface 135 and includes laterally spaced side walls 147A
and angularly spaced end walls 147B. The shaft 139 extends through
the wall 145 and into the vacuum supply conduit 151 where it is
received in a bearing 155 within the conduit. The bearing 155 is
sealed with the vacuum supply conduit 151 so that air is not drawn
in around the shaft 139 where it enters the conduit. The brace 157
and entire conduit 21 are supported by an overhead mount 159.
[0161] A drum rim 161 (FIG. 7) is mounted on the wall 145 of the
drum 137 and has a multiplicity of holes over its surface area to
provide a substantially free movement of fluid, such as air,
through the thickness of the rim. The rim 161 is generally tubular
in shape and extends around the axis of rotation of the shaft 139
near the periphery of the wall 145. The rim 161 is cantilevered
away from the drum wall 145 and has a radially inward-facing
surface positioned closely adjacent to the entrance opening 149 of
the vacuum duct 147. To provide an air resistant seal between the
rim 161 and the entrance opening 149 of the vacuum duct 147, rim
seals 163 are mounted on the inward-facing surface of the rim 161
for sliding, sealing engagement with the walls 147A of the vacuum
duct. Seals (not shown) are also mounted on the end walls 147B of
the vacuum duct 147 for sliding, sealing engagement with the
inward-facing surface of the rim 161. The seals may be formed of a
suitable material such as felt to permit the sliding, sealing
engagements.
[0162] Referring back to FIG. 6, the apparatus 121 further
comprises a forming chamber 171 through which the forming surface
135 is movable conjointly with the drum 137 upon rotation thereof.
More particularly, in the illustrated embodiment the forming
surface 135 moves in a counter-clockwise direction within the
forming chamber 171 generally from an entrance 173 through which
the forming surface enters the forming chamber substantially free
of fibrous material, and an exit 175 through which the forming
surface exits the forming chamber with the pre-stabilized absorbent
structure 101 formed thereon. Alternatively, the drum 137 may
rotate in a clockwise direction relative to the forming chamber
171. The forming chamber 171 is supported by a suitable support
frame (not shown) which may be anchored and/or joined to other
suitable structural components as necessary or desirable.
[0163] An absorbent fiber material, such as in the form of a batt
177 (FIGS. 5 and 6) of absorbent fibers, is delivered from a
suitable supply source (not shown) into a fiberizer 179, which may
be a conventional rotary hammer mill, a conventional rotatable
picker roll or other suitable fiberizing device. The fiberizer 179
separates the batt 177 into discrete, loose absorbent fibers which
are directed from the fiberizer into the interior of the forming
chamber 171. In the illustrated embodiment, the fiberizer 179 is
disposed above the forming chamber 171. However, it is to be
understood that the fiberizer 179 may instead be located remote
from the forming chamber 171 and that absorbent fibers may be
delivered to the interior of the forming chamber in other ways by
other suitable devices and remain within the scope of the present
invention.
[0164] Particles or fibers of superabsorbent material may be
introduced into the forming chamber 171 by employing conventional
mechanisms such as pipes, channels, spreaders, nozzles and the
like, as well as combinations thereof. In the illustrated
embodiment, superabsorbent material is delivered into the forming
chamber 171 via a delivery conduit 181 and nozzle system (not
shown). A binder fiber material is delivered from a suitable binder
fiber supply 183, such as in the form of bales (not shown), to a
suitable opening device 185 to generally separate the binder fiber
material into discrete, loose binder fibers. For example, the
opening device 185 may be suitable for picking, carding, planing or
the like, as well as combinations thereof.
[0165] Selected quantities of binder fiber are then directed to a
metering device 187, and the metering device feeds controlled
quantities of the binder fiber into a binder fiber delivery conduit
189. As an example, the binder fiber metering device 187 may be a
model number CAM-1X12 device which is available from Fiber
Controls, Inc., a business having offices located in Gastonia,
N.C., U.S.A. A blower 191 or other suitable device may be employed
to help the flow of binder fibers through the delivery conduit
189.
[0166] In the illustrated embodiment, the binder fiber conduit 189
delivers the binder fibers into the fiberizer 171 for generally
homogenous mixing with the absorbent fibers such that a homogenous
mixture of absorbent and binder fibers is subsequently delivered
into the forming chamber 171. However, it is understood that the
binder fibers may instead be delivered into the interior of the
forming chamber 171 separate from the absorbent fibers, and at a
location other than at the delivery point at which the absorbent
fibers are directed by the fiberizer 179 into the forming
chamber.
[0167] Where the binder fibers are directed into the forming
chamber 171 at a location which is closer to the entrance 173 of
the forming chamber, the binder fibers will be more concentrated
toward an inner or forming surface side 193 (FIG. 6) or major face
of the absorbent structure 101 formed on the forming surface 135.
Where the binder fibers are directed into the forming chamber 171
at a location which is closer to the exit 175 of the forming
chamber, the binder fibers will be more concentrated toward an
outer or free-surface side 195 (FIG. 6) or major face of the
absorbent structure 101. As an alternative, the binder fibers may
be combined with or otherwise incorporated into the source of the
absorbent fibers instead of being separately delivered to the
airforming device 131. For instance, the binder fibers may be
blended with the absorbent fibers before the absorbent fibers are
formed into a supply roll (e.g. the batt 177).
[0168] The foraminous forming surface 135 is defined in the
illustrated embodiment by a series of mold elements, or form
members 201 which are arranged end-to-end around the periphery of
the forming drum 137 and independently attached to the drum. As may
be seen in FIG. 8, the form members 201 each define a substantially
identical pattern in which fibrous material is collected. The
patterns correspond to a desired length, width and thickness of
individual absorbent structures 101 which repeats over the
circumference of the drum 137. However, partially repeating or
non-repeating pattern shapes may be used with the present
invention. It is also understood that a continuous, un-patterned
absorbent structure may be formed on the forming surface 135, such
as where the forming surface is flat or where the formed absorbent
structure is generally rectangular, and is subsequently processed
(e.g., cut or otherwise formed) to a desired shape.
[0169] With general reference now to FIGS. 8-10, the form members
201 comprise a foraminous member 205 which is operatively located
on and secured to the forming drum 135. The foraminous member 205
may include a screen, a wire mesh, a hard-wire cloth, a perforated
member or the like, as well as combinations thereof. In the
particular embodiment shown in FIG. 10, the foraminous member 205
is fluted to define open channels 209 which extend generally
radially to allow a substantially free flow of air or other
selected gas from the outer surface of the drum 137 toward the
interior of the drum. The channels 209 can have any desired
cross-sectional shape, such as circular, oval, hexagonal,
pentagonal, other polygonal shape or the like, as well as
combinations thereof.
[0170] With particular reference to FIG. 10, the radially outermost
surface defined by the foraminous member 205 can be configured with
a non-uniform depth-wise (e.g., z-direction 127) surface contour to
provide a desired non-uniform thickness of the pre-stabilized
absorbent structure 101 formed on the forming surface 135. In
desired arrangements, the z-direction 127 variation of the surface
contour can have a selected pattern which may be regular or
irregular in configuration. For example, the pattern of the surface
contour can be configured to substantially provide a selected
repeat-pattern along the circumferential dimension of the forming
drum 137.
[0171] The surface contour of the foraminous member 205 shown in
FIG. 10 thus defines longitudinally opposite end regions having a
first average depth and a central region having a second average
depth that is greater than the first average depth. Each end region
with the first average depth can provide a lower-basis-weight
region and/or thickness of the absorbent structure 101 formed on
the forming surface 135, and the central region with the greater
second average depth can provide a relatively higher-basis-weight
and/or thickness region of the absorbent structure. Desirably, each
region with the first average depth can be substantially contiguous
with an adjacent region with the greater second depth. It is also
understood that the foraminous member 205 may be configured to have
a z-direction 127 surface contour across the width of the forming
surface 135 for providing a non-uniform basis weight and/or
thickness across the width of the absorbent structure 101 formed on
the forming surface.
[0172] In desired arrangements, the surface contour of the
foraminous member 205 defines a generally trapezoidal shape.
Alternatively, the contour may define a domed shape or may be flat.
In the illustrated embodiment, the depth profile defined by the
foraminous member 205 forms a pocket region 211 extending in the
machine direction 123 along a portion of the length of the forming
surface 135 and across a central portion of the width thereof for
forming the absorbent structure shown in FIG. 4.
[0173] In a further aspect, one or more non-flow regions of the
forming surface may be formed by employing a suitable blocking
mechanism (not shown) which covers or otherwise occludes the flow
of air through selected regions of the forming surface 135. As a
result, the blocking mechanism can deflect or reduce the amount of
fibers deposited on the areas of the forming surface 135 covered by
the blocking mechanism. The blocking mechanism can optionally be
configured to form other desired features of the absorbent
structure 101, such as a series of key notches (not shown) on the
formed absorbent structure. The key notches can, for example,
provide a sensing point for locating and positioning a subsequent
severing of a web of longitudinally connected absorbent structures
101 formed on the forming surface 135 into discrete absorbent
structures.
[0174] Still referring to FIGS. 8-10, the form members 201 can also
include one or more side-masking members 213, also sometimes
referred to as contour rings, configured to provide a desired shape
(e.g., width profile) to the absorbent structure 101. For example,
in the illustrated embodiment the side-masking members 213 are
provided by a pair of laterally opposed ring members which extend
circumferentially around the forming drum 137 in laterally
(cross-direction 125) opposed relationship with each other. Each of
the members 213 has a non-uniform inner side wall 215 along its
respective length so that the laterally opposed inner side walls of
the side-masking members 213 define the width profile of the
absorbent structure 101 formed on the forming surface 135. More
particularly, the inner side walls 215 of the side-masking members
213 have a generally serpentine contour as they extend in the
machine direction 123. As a result, the side-masking members 213
provide alternating narrower and wider regions of the form members
201. Accordingly, the absorbent structure 101 delivered from the
airforming device 131 can have a width profile which is non-uniform
along at least a portion of the length of the structure.
[0175] In another feature, at least one of the side-masking members
213 can include one or more key tabs (not shown). The individual
key tabs may, for example, be employed for marking or otherwise
identifying each intended absorbent structure 101 length along the
circumference of the forming drum 137. Such side-masking members
213 can be particularly advantageous when the airforming device 131
is employed to produce absorbent structures for use in disposable,
shaped absorbent articles, such as diapers, children's training
pants, feminine care products, adult incontinence products and the
like.
[0176] It is understood that the inner side walls 215 of the
side-masking members 213 can instead be generally straight (e.g.
parallel to the machine direction 123) to produce a substantially
rectangular, ribbon shaped absorbent structure 101. It is also
understood that the side edges 105 of the absorbent structure 101
can alternatively be provided by cutting and removal, cutting and
folding, or the like, as well as combinations thereof.
[0177] While the forming surface 135 is illustrated herein as being
part of the forming drum 137, it is to be understood that other
techniques for providing the forming surface 135 may also be
employed without departing from the scope of the present invention.
For example, the forming surface 135 may be provided by an endless
forming belt (not shown). A forming belt of this type is shown in
U.S. Pat. No. 5,466,409, entitled FORMING BELT FOR
THREE-DIMENSIONAL FORMING APPLICATIONS by M. Partridge et al. which
issued on Nov. 14, 1995.
[0178] In operation to make a formed, non-woven pre-stabilized
absorbent structure, e.g., prior to activation of the binder fibers
to form inter-fiber bonds within the absorbent structure, the
vacuum source 153 (FIG. 7) creates a vacuum in the vacuum duct 147
relative to the interior of the forming chamber 171. As the forming
surface 135 enters and then moves through the forming chamber 171
toward the exit 175 thereof, the absorbent fibers, binder fibers
and superabsorbent material within the forming chamber are
operatively carried or transported by an entraining air stream and
drawn inward by the vacuum toward the foraminous forming surface.
It is understood that the absorbent fibers, superabsorbent
materials and binder fibers may be entrained in any suitable fluid
medium within the forming chamber 171. Accordingly, any reference
herein to air as being the entraining medium should be understood
to be a general reference which encompasses any other operative
entraining fluid. Air passes inward through the forming surface 135
and is subsequently passed out of the drum 137 through the vacuum
supply conduit 151. Absorbent fibers, binder fibers and
superabsorbent materials are collected by the form members 201 to
thereby form the pre-stabilized absorbent structure 101.
[0179] It is understood that the level or strength of the vacuum
suction can be selectively regulated to control the density of the
absorbent structure 101 formed on the forming surface 135. A
relatively greater suction strength can be employed to produce a
relatively higher density, or low porosity, in the absorbent
structure 101, and a relatively lower suction strength can be
employed to produce a relatively lower density, or high porosity,
in the absorbent structure. The specific level of suction strength
will depend upon the specific flow characteristics present in the
forming chamber 171. It is readily apparent that a desired suction
strength can be found by employing a short, iterative series of
well known trial steps. The density of the absorbent structure 101
prior to activation of the binder fibers can be important for
controlling the desired functional properties of the subsequently
stabilized absorbent structure.
[0180] Subsequently, the drum 137 carrying the absorbent structure
101 passes out of the forming chamber 171 through the exit 175 to a
scarfing system, generally indicated at 271 in FIGS. 5 and 6, where
excess thickness of the absorbent structure can be trimmed and
removed to a predetermined extent. The scarfing system 271 includes
a scarfing chamber 273 and a scarfing roll 275 positioned within
the scarfing chamber. The scarfing roll 275 abrades excess fibrous
material from the absorbent structure 101, and the removed
materials are transported away from the scarfing chamber 273 within
a suitable discharge conduit as is well known in the art. The
removed fibrous material may, for example, be recycled back into
the forming chamber 171 or the fiberizer 179, as desired.
Additionally, the scarfing roll 275 can rearrange and redistribute
the fibrous material along the machine-direction 123 of the
absorbent structure 101 and/or along the lateral or cross-machine
direction 125 of the absorbent structure.
[0181] The rotatable scarfing roll 275 is operatively connected and
joined to a suitable shaft member (not shown), and is driven by a
suitable drive system (not shown). The drive system may include any
conventional apparatus, such as a dedicated motor, or a coupling,
gear or other transmission mechanism operatively connected to the
motor or drive mechanism used to rotate the forming drum 137. The
scarfing system 271 can provide a conventional trimming mechanism
for removing or redistributing any excess thickness of the
absorbent structure 101 that has been formed on the forming surface
135. The scarfing operation can yield an absorbent structure 101
having a selected contour on a major face-surface thereof (e.g.,
the free surface side 193 in the illustrated embodiment) that has
been contacted by the scarfing roll 275. For example, the scarfing
roll 275 may be configured to provide a substantially flat surface
along the scarfed surface of the absorbent structure 101, or may
optionally be configured to provide a non-flat surface. The
scarfing roll 275 is disposed in spaced adjacent relationship with
the forming surface 135, and the forming surface is translated past
the scarfing roll upon rotation of the drum 137.
[0182] The scarfing roll 275 of the illustrated embodiment rotates
in a clockwise direction which is counter to the direction of
rotation of the drum 137. Alternatively, the scarfing roll 275 may
be rotated in the same direction as the forming surface 135 on the
forming drum 137. In either situation, the rotational speed of the
scarfing roll 275 should be suitably selected to provide an
effective scarfing action against the contacted surface of the
formed absorbent structure 101. In like manner, any other suitable
trimming mechanism may be employed in place of the scarfing system
271 to provide a cutting or abrading action to the fibrous
absorbent structure 101 by a relative movement between the
absorbent structure and the selected trimming mechanism.
[0183] After the scarfing operation, the portion of the forming
surface 135 on which the absorbent structure 101 is formed can be
moved to a release zone of the apparatus 121 disposed exterior of
the forming chamber 171. In the release zone, the absorbent
structure 101 is drawn away from the forming surface 135 onto a
conveyor, which is indicated generally at 281 in FIGS. 5 and 6. The
release can be assisted by the application of air pressure from the
interior of the drum 137. The conveyor 281 receives the formed
absorbent structure 101 from the forming drum 137 and conveys the
absorbent structure to a collection area or to a location for
further processing (not shown). Suitable conveyors can, for
example, include conveyer belts, vacuum drums, transport rollers,
electromagnetic suspension conveyors, fluid suspension conveyors or
the like, as well as combinations thereof.
[0184] In the illustrated embodiment, the conveyor 281 includes an
endless conveyor belt 283 disposed about rollers 285. A vacuum
suction box 287 is located below the conveyor belt 283 to draw the
absorbent structure 101 away from the forming surface 135. The belt
283 is perforate and the vacuum box 287 defines a plenum beneath
the portion of the belt in close proximity to the forming surface
so that the vacuum within the vacuum box acts on the absorbent
structure 101 on the forming surface 135. Removal of the absorbent
structure 101 from the forming surface 135 can alternatively be
accomplished by the weight of the absorbent structure, by
centrifugal force, by mechanical ejection, by positive air pressure
or by some combination thereof or by another suitable method
without departing from the scope of this invention. As an example,
in the illustrated embodiment, the absorbent structures 101 exiting
the forming chamber are interconnected end-to-end to form a web or
series of absorbent structures, each of which has a selected shape
that substantially matches the shape provided by the corresponding
form members 201 used to form each individual absorbent
structure.
[0185] Referring now to FIG. 5, after the pre-stabilized absorbent
structures 101 are transferred from the forming surface 135 to the
conveyor 281, each absorbent structure is subsequently transported
to an activation system 304 wherein the binder fibers are activated
to form inter-fiber bonds within the absorbent structure. In one
embodiment, the binder activation system 304 includes an activation
chamber 306 through which each absorbent structure 101 passes, and
a generator 308 for radiating electromagnetic energy within the
activation chamber as each absorbent structure passes therethrough.
For example, a suitable microwave generator 308 can produce an
operative amount of microwave energy, and can direct the energy
through a suitable wave-guide 310 to the activation chamber
306.
[0186] In one embodiment, the electromagnetic energy may be radio
frequency (RF) energy having an RF frequency which is at least a
minimum of about 0.3 megahertz (MHz). The frequency can
alternatively be at least about 300 MHz, and can optionally be at
least about 850 MHz. In other aspects, the frequency can be up to a
maximum of about 300,000 MHz, or more. The frequency can
alternatively be up to about 30,000 MHz, and can optionally be up
to about 2,600 MHz. In a particular embodiment, the radio frequency
is desirably about 27 MHz. In another embodiment, the
electromagnetic energy may be microwave energy in the range of
about 915 MHz to about 2450 MHz.
[0187] In a particular arrangement, the electromagnetic energy can
operatively heat the binder fibers to a temperature above the
melting point of the binder fiber material. The melted binder
fibers can then adhere or otherwise bond and operatively connect to
the absorbent fibers, to the superabsorbent material and/or to
other binder fibers within the absorbent structure. The binder
fibers may also be activated substantially without heating up the
entire mass of the absorbent structure 101. In a particular
feature, the binder fibers can be rapidly activated while
substantially avoiding any excessive burning of the absorbent
structure 101.
[0188] The heating and melt activation of the binder fibers can be
produced by any operative mechanism available in the absorbent
structure 101. For example, the electromagnetic energy may heat
water vapor present within the absorbent structure 101, and the
heated vapor can operatively melt the binder fibers. In another
mechanism, the electromagnetic energy can be absorbed by the binder
fibers and the absorbed energy can operatively heat and melt the
binder fibers.
[0189] The total residence time of the absorbent structure 101
within the activation chamber 306 can provide a distinctively
efficient activation period. In a particular aspect, the activation
period can be at least a minimum of about 0.002 sec. The activation
period can alternatively be at least about 0.005 sec, and can
optionally be at least about 0.01 sec. In other aspects, the
activation period can be up to a maximum of about 3 sec. The
activation period can alternatively be up to about 2 sec, and can
optionally be up to about 1.5 sec.
[0190] The activation chamber 304 can be a tuned chamber within
which the electromagnetic energy can produce an operative standing
wave. In a particular feature, the activation chamber 304 can be
configured to be a resonant chamber. Examples of suitable
arrangements for the resonant, activation chamber system are
described in a U.S. Pat. No. 5,536,921 entitled SYSTEM FOR APPLYING
MICROWAVE ENERGY IN SHEET-LIKE MATERIAL by Hedrick et al. which has
an issue date of Jul. 16, 1996; and in U.S. Pat. No. 5,916,203
entitled COMPOSITE MATERIAL WITH ELASTICIZED PORTIONS AND A METHOD
OF MAKING THE SAME by Brandon et al which has a issue date of Jun.
29, 1999. The entire disclosures of these documents are
incorporated herein by reference in a manner that is consistent
herewith. Another suitable activation system for activating the
binder fibers is disclosed in co-assigned U.S. patent application
Ser. No. 10/037,385, filed Dec. 20, 2001 and entitled Method and
Apparatus for Making On-Line Stabilized Absorbent Materials.
[0191] The absorbent structure 101 exiting the activation chamber
304 can also be selectively cooled or otherwise processed following
heating of the binder fibers. The cooling of the absorbent
structure 101 may be provided by a cooling system that includes:
chilled air, a refrigerated atmosphere, radiant cooling,
transvector cooling, ambient air cooling, or the like, as well as
combinations thereof. As representatively shown in FIG. 5, the
cooling system may include a chilled-air supply hood 321, a vacuum
conveyor 323, a blower 325 and a chiller or other refrigeration
unit 327. The refrigeration unit 327 can provide a suitable coolant
to a heat exchanger 329, and the blower can circulate air through
the heat exchanger for cooling. The cooled air can be directed into
the supply hood 321 and onto the absorbent structure 101. The air
can then be drawn out of the hood 321 for recirculation through the
heat exchanger 329.
[0192] In a particular aspect, the absorbent structure 101 can be
cooled to a setting temperature which is below the melting
temperature of the binder fiber material. In another aspect, the
absorbent structure 101 can be cooled to a temperature of not more
than a maximum of 200.degree. C. within a selected setting distance
downstream of the activation chamber 304. In a further feature, the
absorbent structure 101 can be cooled to a temperature of not more
than a maximum of 150.degree. C. within the selected setting
distance. Accordingly, the setting distance can be measured after
ending the exposure of the absorbent structure 101 to the
high-frequency electromagnetic energy in the activation chamber
304. In a particular feature, the setting distance can be a minimum
of about 0.5 m. The setting distance can alternatively be at least
a minimum of about 0.75 m, and can optionally be at least about 1
m. In another feature, the setting distance can be a maximum of not
more than about 30 m. The setting distance can alternatively be not
more than about 20 m, and can optionally be not more than about 10
m.
[0193] In another aspect, an incremental portion of the heated
absorbent structure 101 may be cooled to the desired setting
temperature within a distinctive setting period, as determined from
the time that the incremental portion of the activated structure
exits the activation chamber 304. Accordingly, the setting period
can be measured after ending the exposure of the absorbent
structure to the high-frequency electromagnetic energy in the
activation chamber 304. In a particular feature, the setting period
can be a minimum of about 0.05 sec. The setting period can
alternatively be at least a minimum of about 0.075 sec, and can
optionally be at least about 0.1 sec. In another feature, the
setting period can be a maximum of not more than about 3 sec. The
setting period can alternatively be not more than about 2 sec, and
can optionally be not more than about 1 sec.
[0194] The temperature of the absorbent structure 101 can be
determined by employing an infrared scanner, such as a model No.
LS601RC60 available from Land Infrared, a business having offices
located in Bristol, Pa., U.S.A. With this device, the temperature
can be determined by aiming the measurement probe at the centerline
of the structure 101, and setting up the probe (in accordance with
the instruction manual) at a separation distance of 12 inches, as
measured perpendicular to the structure. Alternatively, a
substantially equivalent device may be employed.
[0195] The stabilized absorbent structure 101 may also be
compressed (e.g., by subjecting the structure to a debulking
operation) to provide a desired thickness and density to the
stabilized absorbent structure. In a desired aspect, the debulking
is conducted after the absorbent structure has been cooled. As
representatively shown, the debulking operation can be provided by
a pair of counter-rotating nip rollers 331. The debulking operation
can alternatively be provided by a converging conveyor system,
indexed platens, elliptical rollers, or the like, as well as
combinations thereof.
[0196] In a particular aspect, the thickness of the absorbent
structure following debulking can be a minimum of about 0.5 mm. The
debulked thickness can alternatively be at least about 1 mm, and
can optionally be at least about 2 mm. In another aspect, the
debulked thickness can be up to a maximum of about 25 mm. The
debulked thickness can alternatively be up to about 15 mm, and can
optionally be up to about 10 mm.
[0197] In another aspect, the debulked stabilized absorbent
structure 101 can have a density which is at least a minimum of
about 0.05 g/cm.sup.3. The debulked density can alternatively be at
least about 0.08 g/cm.sup.3, and can optionally be at least about
0.1 g/cm.sup.3. In further aspects, the debulked density can be up
to a maximum of about 0.5 g/cm.sup.3, or more. The debulked density
can alternatively be up to about 0.45 g/cm.sup.3, and can
optionally be up to about 0.4 g/cm.sup.3.
[0198] In optional configurations, the stabilized absorbent
structure 101 may be cut or otherwise divided to provide a desired
lateral shaping (e.g., width profile) of the structure, and/or to
provide a laterally contoured structure. The cutting system may,
for example, include a die cutter, a water cutter, rotary knives,
reciprocating knives or the like, as well as combinations thereof.
The shaping may be conducted prior to and/or after the absorbent
structure 101 is subjected to the activation of the binder fiber
with the selected activation system 304.
[0199] It will be appreciated that details of the foregoing
embodiments, given for purposes of illustration, are not to be
construed as limiting the scope of this invention. Although only a
few exemplary embodiments of this invention have been described in
detail above, those skilled in the art will readily appreciate that
many modifications are possible in the exemplary embodiments
without materially departing from the novel teachings and
advantages of this invention. For example, features described in
relation to one embodiment may be incorporated into any other
embodiment of the invention.
[0200] Accordingly, all such modifications are intended to be
included within the scope of this invention, which is defined in
the following claims and all equivalents thereto. Further, it is
recognized that many embodiments may be conceived that do not
achieve all of the advantages of some embodiments, particularly of
the preferred embodiments, yet the absence of a particular
advantage shall not be construed to necessarily mean that such an
embodiment is outside the scope of the present invention.
[0201] When introducing elements of the present invention or the
preferred embodiment(s) thereof, the articles "a", "an", "the" and
"said" are intended to mean that there are one or more of the
elements. The terms "comprising", "including" and "having" are
intended to be inclusive and mean that there may be additional
elements other than the listed elements.
[0202] As various changes could be made in the above constructions
without departing from the scope of the invention, it is intended
that all matter contained in the above description or shown in the
accompanying drawings shall be interpreted as illustrative and not
in a limiting sense.
* * * * *