An absorbent core comprising substantially continuous zones of one or more high fluid distribution structures and discontinuous zones of fluid absorption structures surrounding the one or more high fluid distribution structures, wherein the one or more high fluid distribution structures are arranged to distribute fluid across the absorbent core at a speed that is faster than the speed of fluid distribution across the absorbent core by said discontinuous fluid absorption structures, and wherein said continuous zones extend along a path that is substantially parallel to at least a portion of the perimeter of the core, said portion of the perimeter of the core comprising at least a portion of the sides of the core and one of the ends of the core.

Provided is a composite sheet that is particularly useful as an AQDL component in absorbent articles. The composite sheet includes a fluid acquisition component and an airlaid component. The airlaid component may include one or more airlaid layers that are successively formed overlying each other. Each of the airlaid layers are adjacent to, and in direct contact with, immediately adjacent layers of the airlaid component so that adjacent layers are in fluid communication with respect to each other. The fluid acquisition component includes a nonwoven fabric comprising a carded nonwoven fabric comprised of a plurality of staple fibers that are air through bonded to each other to form a coherent nonwoven fabric. The airlaid layer(s) include a blend of cellulose and non-cellulose staple fibers. The staple fibers may be bicomponent fibers having a polyethyelene sheath and a polypropylene or polyethylene terephthalate core, and mixtures of such fibers.

The present invention is an equipment and a process for the handling of fibrous webs that comprise particulate additives, which are positioned within interstices between the fibers and/or on the surface of the webs. By applying the present invention, predetermined regions are created in the web, which are essentially free of the particulate additives.

A nonwoven fabric. The nonwoven fabric can include a first surface and a second surface and a visually discernible pattern of three-dimensional features on one of the first or second surface. Each of the three-dimensional features can define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property. The nonwoven further has a plurality of apertures, wherein at least a portion of the aperture abuts at least one of the first region and the second region of the microzone.

A method for forming porous fibers is provided. The fibers are formed from a thermoplastic composition containing a continuous phase, which includes a matrix polymer, and a nanoinclusion additive that is at least partially incompatible with the matrix polymer so that it becomes dispersed within the continuous phase as discrete nano-scale phase domains. The method generally includes traversing a bundle of the fibers over one or more draw bars that are in contact with a fluidic medium (e.g., water). In certain embodiments, for example, the draw bar(s) are submerged in the fluidic medium. The fluidic medium is lower than the melting temperature of the matrix polymer.

A method for making nonwoven fabric. The nonwoven fabric can include three-dimensional features that define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property. The nonwoven further has a plurality of apertures, wherein at least a portion of the aperture abuts at least one of the first region and the second region of the microzone.

A nonwoven having a high affinity for an active ingredient is proved, the nonwoven having at least one high surface area fiber in addition to the active ingredient.

Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming an absorbent core may comprise moving a forming surface in a machine direction, creating a pressure differential across the forming surface, advancing a base carrier sheet on the forming surface in the machine direction, applying a first adhesive onto the base carrier sheet, and applying a first quantity of particulate material onto the first adhesive at a first cross-machine direction width. The method may further comprise depositing a matrix of material onto the first quantity of particulate material at a second cross-machine direction width, the matrix of material comprising a second quantity of particulate material and a second adhesive, wherein the second cross-machine direction width is smaller than the first cross-machine direction width, and wherein the second quantity of particulate material and the adhesive are pre-mixed prior to deposition onto the first quantity of particulate material.

An absorbent core (28) for use in an absorbent article, the absorbent core extending in a transversal direction (x) and a longitudinal direction (y), the absorbent core comprising: a fluid-permeable top layer (41), a bottom layer (42), and a central layer (43) sandwiched between the top layer and the bottom layer. the central layer is a high loft fibrous nonwoven layer, in particular having a density of less than 0.200 g/cc, measured at a pressure of 4.14 kPa. Superabsorbent polymer particles (60) are blended with the fibers of the central layer, except for one, two or more longitudinally-extending channels (26) substantially free of superabsorbent polymer particles. The superabsorbent polymer particles may have a UPM of below 30×10.sup.−7 cm.sup.3.Math.s/g, wherein the UPM is measured by the Urine Permeability Measurement Test described herein.

A method for producing an absorbent structure for absorbent sanitary articles, comprising the steps of: advancing a first non-woven layer at a first speed, with a first surface of said first non-woven layer facing a suction chamber, distributing superabsorbent granular material on a second surface of said first non-woven layer opposite to said first surface, volumizing said first non-woven layer by means of a toothed portion that penetrates into said first non-woven layer through said second surface and movable with respect to said first non-woven layer with a speed difference.