ABSORBENT LAMINATES, ABSORBENT CORES AND DISPOSABLE ARTICLES UTILIZING THE ABSORBENT LAMINATES, AND RELATED METHODS

Abstract

Absorbent multi-layer laminates with SAP on both sides of a middle substrate that comprises wettable cellulosic fibers. Also absorbent cores including such absorbent laminates. Absorbent articles such as protective underwear, adult briefs, baby diapers and nursing pads including such absorbent cores, and patient-support pads such as underpads and sacral pads including such absorbent laminates and cores.

Claims

1. An absorbent laminate comprising: a first sublayer comprising super-absorbent polymer (SAP) particles and an adhesive supporting the SAP particles in a porous matrix, the SAP particles in the first sublayer having a basis weight of from 20 grams per square meter (gsm) to 130 gsm; a second sublayer comprising SAP particles and an adhesive supporting the SAP particles in a porous matrix, the SAP particles in the second sublayer having a basis weight of from 20 gsm to 130 gsm; and a third sublayer disposed between, and bonded to each of, the first and second layers, the third sublayer comprising a nonwoven web of wettable cellulosic fibers, the nonwoven web having a basis weight of from 6 gsm to 80 gsm.

2. The absorbent laminate of claim 1, where the third sublayer comprises a spunlace nonwoven web having a basis weight of from 20 gsm to 80 gsm.

3. The absorbent laminate of claim 2, where the third sublayer comprises a tissue with a basis weight of from 15 gsm to 35 gsm.

4. The absorbent laminate of claim 1, where the third sublayer comprises regenerated cellulosic fibers.

5. The absorbent laminate of claim 1, further comprising: a fourth sublayer bonded to the first sublayer such that the first sublayer is disposed between the fourth sublayer and the third sublayer, the fourth sublayer comprising tissue; and a fifth sublayer bonded to the second sublayer such that the second sublayer is disposed between the fifth sublayer and the third sublayer, the fifth sublayer comprising tissue.

6. The absorbent laminate of claim 5, where the absorbent laminate has a caliper of less than 1.3 millimeters (mm).

7. The absorbent laminate of claim 6, where the absorbent laminate has tensile strength in at least one direction of at least 40 Newtons per 50 mm (N/50 mm).

8. The absorbent laminate of claim 5, where the tissue of at least one of the fourth and fifth sublayers is creped and/or through-air dried.

9. The absorbent laminate of claim 5, where a thickness of the second sublayer is equal to a thickness of the first sublayer.

10. The absorbent laminate of claim 5, where the basis weight of the SAP particles in the second sublayer is equal to the basis weight of the SAP particles in the first sublayer.

11. The absorbent laminate of claim 10, where a basis weight of the adhesive in the first sublayer is from 0.5 gsm to 5 gsm, and a basis weight of the adhesive in the second sublayer is from 0.5 gsm to 5 gsm.

12. A method of making an absorbent laminate, the method comprising: distributing adhesive and super-absorbent polymer (SAP) particles on a first side of a nonwoven web of wettable cellulosic fibers defining a first sublayer such that the adhesive supports the SAP particles in a porous matrix to define a second sublayer, the nonwoven web having a basis weight of from 6 grams per square meter (gsm) to 80 gsm, the SAP particles in the second sublayer having a basis weight of from 20 gsm to 80 gsm; distributing adhesive and super-absorbent polymer (SAP) particles on a second side of a nonwoven web of wettable cellulosic fibers such that the adhesive supports the SAP particles in a porous matrix to define a third sublayer, the SAP particles in the third sublayer having a basis weight of from 20 gsm to 80 gsm.

13. The method of claim 12, further comprising: while the adhesive of the first sublayer is tacky, applying a fourth sublayer to the first sublayer such that the fourth sublayer bonds to the first sublayer with the first sublayer disposed between the fourth sublayer and the third sublayer, the fourth sublayer comprising tissue; and while the adhesive of the second sublayer is tacky, applying a fifth sublayer to the second sublayer such that the fifth sublayer bonds to the second sublayer with the second sublayer is disposed between the fifth sublayer and the third sublayer, the fifth sublayer comprising tissue.

14. An absorbent core for a disposable absorbent article, the absorbent core comprising: one or more pieces of the absorbent laminate of any of claims 1-11 defining a plurality of layers of the absorbent laminate.

15. The absorbent core of claim 14, where a single piece of the absorbent laminate is folded to define the plurality of layers of the absorbent laminate.

16. The absorbent core of claim 14, where multiple pieces of the absorbent laminate are stacked to define the multiple layers of the absorbent laminate.

17. The absorbent core of claim 14, further comprising: an additional piece of the absorbent laminate of claim 5 coupled to an outermost one of the sublayers of the absorbent laminate.

18. The absorbent core of claim 17, where the plurality of layers of the absorbent laminate have a combined width and a combined length that is greater than the combined width, the combined length extending from a first end to a second end of the absorbent core, the additional piece has a length that differs from the combined length.

19. The absorbent core of claim 18, where the combined length of the plurality of layers of the absorbent laminate is from 50% to 70% of the length of the additional piece of the absorbent laminate.

20. The absorbent core of claim 19, where the plurality of the layers of the absorbent laminate are defined by a first piece of the absorbent laminate that is folded, and the additional piece of the absorbent laminate is not folded.

21. The absorbent core of claim 14, where the absorbent core is configured to exhibit a resiliency greater than 70% when partially hydrated.

22. The absorbent core of claim 14, where the absorbent core is configured to exhibit a Stress-Based Softness for a second compression cycle, at a pressure of 510.sup.3 Pa, of less than 15010.sup.3 Pa when a 100 mm100 mm section of the absorbent core is dosed with 145 milliliters (mL) of water.

23. The absorbent core of claim 14, where the absorbent core is configured to exhibit a Strain-Based Softness for a second compression cycle, at a strain of 10%, of less than 410.sup.3 Pa when a 100 mm100 mm section of the absorbent core is dosed with 100 milliliters (mL) of water.

24. A disposable absorbent article comprising: a liquid-permeable topsheet; a liquid-impermeable backsheet; and an absorbent core of claim 14 disposed between the topsheet and the backsheet.

25. The absorbent article of claim 24, where the absorbent article does not include a discrete acquisition-distribution layer in addition to the absorbent core.

26. The absorbent article of claim 24, where the absorbent article is a bed pad, and the absorbent core has a width of at least 12 inches and a length of at least 18 inches.

27. A method of making an absorbent core for disposable absorbent articles, the method comprising: stacking a plurality of layers of the absorbent laminate of any of claim 1.

28. The method of claim 27, where the plurality of layers are stacked by folding a single piece of the absorbent laminate over itself.

29. A disposable patient-support article comprising: a support core comprising one or more pieces of the absorbent laminate of any of claims 1-11 that define a plurality of layers of the absorbent laminate; and a liquid impermeable layer coupled to the support core; where the support core has a width of at least 8 inches and a length of at least 8 inches.

30. The patient-support article of claim 29, further comprising: an additional piece of the absorbent laminate of claim 5 coupled to an upper outermost one of the sublayers of the absorbent laminate.

31. The patient-support article of claim 29, where the support core is a first support core, and the patient-support article further comprises: a second support core comprising one or more pieces of the absorbent laminate of any of claims 1-11 that define a plurality of layers of the absorbent laminate; where the second support core is coupled to the liquid impermeable layer and laterally spaced from the first support core.

32. The patient-support article of claim 29, where the liquid-impermeable layer is a backsheet, and the patient-support article further comprises: a topsheet; where the support core is disposed between the backsheet and the topsheet such that the backsheet and topsheet form an enclosure in which the support core is disposed.

33. The patient-support article of claim 32, where the topsheet is liquid-permeable.

34. The patient-support article of claim 32, where the topsheet is liquid-impermeable.

35. The patient-support article of claim 32, where the topsheet is vapor-permeable.

36. The patient-support article of claim 29, where the patient-support pad is configured to permit liquid to be delivered to the SAP particles prior to positioning the patient-support pad under a patient.

37. The patient-support article of claim 36, where the liquid-impermeable layer defines an enclosure in which the support core is disposed, and the patient-support pad further comprises: a container holding a volume of liquid sufficient to, when absorbed by the SAP particles, swell at least a portion of the SAP particles to at least a desired resiliency; where the container is disposed in the enclosure and configured to be ruptured to release the liquid within in the enclosure.

38. The patient-support article of claim 29, where the backsheet and topsheet cooperate to define at least a portion of an adult protective underwear or brief, and the adult protective underwear or brief is configured such that when worn by a user the support core is aligned with at least a portion of one of the wearer's hips.

39. The patient-support article of claim 29, where the backsheet and topsheet cooperate to define at least a portion of a pad that is configured to be coupled to an absorbent article.

40. The patient-support article of claim 29, where the backsheet and topsheet cooperate to define at least a portion of a pad having a dermal adhesive configured to adhere the pad directly to a patient's skin.

41. The patient-support article of claim 29, where the pad is shaped or contoured to overlie a portion of a human body.

42. The patient-support article of claim 29, where the backsheet and topsheet cooperate to define at least a portion of a chassis of a bed pad or underpad.

43. The patient-support article of claim 29, where the backsheet and topsheet cooperate to define at least a portion of a chassis of a seat cushion.

44. A method comprising: delivering liquid to the support core of a disposable patient-support article of claim 29; allowing the support core to absorb a sufficient volume of the liquid to increase the resilience in compression of the support core; and disposing, after the liquid has been delivered to the support core, the patient-support article between at least a portion of a patient and a surface supporting the at least a portion of the patient.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0042] The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers.

[0043] FIG. 1A depicts a bottom plan view of a prior art disposable absorbent article, specifically adult protective underwear, in an open configuration.

[0044] FIG. 1B depicts a perspective view of the protective underwear of FIG. 1A in a closed configuration.

[0045] FIG. 2 depicts a schematic cross-sectional view of a first embodiment of an absorbent laminate.

[0046] FIG. 3 depicts a schematic cross-sectional view of a second embodiment of an absorbent laminate.

[0047] FIGS. 4A-4C depict stages of a method of manufacturing the laminate of FIG. 2.

[0048] FIG. 4D depicts a further stage of a method of manufacturing the laminate of FIG. 3.

[0049] FIG. 5 depicts a perspective view of an embodiment of a core utilizing an embodiment of the present absorbent laminates.

[0050] FIG. 6 depicts a side view of the core of FIG. 4.

[0051] FIG. 7A depicts a schematic cross-sectional view of a first configuration of the core of FIG. 5 taken along the line 7-7 of FIG. 5.

[0052] FIG. 7B depicts a schematic cross-sectional view of a second configuration of the core of FIG. 5 taken along the line 7-7 of FIG. 5.

[0053] FIGS. 8A-8C depict alternate configurations of the present folded cores.

[0054] FIGS. 9A and 9B depict compression properties of a traditional fluff/SAP core and the core of FIG. 5, respectively, over several compression cycles after absorbing fluid.

[0055] FIG. 10 depicts a plan view of an embodiment of a disposable patient-support pad.

[0056] FIG. 11 depicts an exploded, cross-sectional view of a first configuration of the patient-support pad of FIG. 10.

[0057] FIG. 12 depicts an exploded, cross-sectional view of a second configuration of the patient-support pad of FIG. 10.

[0058] FIG. 13 depicts a bottom plan view of a disposable absorbent article, specifically adult protective underwear, including patient-support pads and in an open configuration.

[0059] FIGS. 14-16 depict various views of embodiments of the present patient-support pads.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0060] Referring now to FIG. 2, shown there and designated by the reference numeral 100 is a first embodiment of an absorbent material. As shown, material 100 is a laminate that comprises a first sublayer 104, a second sublayer 108, and a third sublayer 112 disposed between the first and second sublayers. Third sublayer provide a middle substrate for the first and second sublayers 104, 108, which are more absorbent than third sublayer 112. As shown, the sublayers are arranged such that a lower side of first sublayer 104 contacts an upper side of third sublayer 112, and an upper side of second sublayer 108 contacts a lower side of third sublayer 112. In the embodiment shown, each of the sublayers 104, 108, 112 has a substantially uniform thickness across its respective area; in other embodiments, the respective thicknesses of the sublayers may vary. In some embodiments, each of first, second, and third sublayers 104, 108, 112 have similar thicknesses.

[0061] In the embodiment shown, the middle substrate sublayer, i.e., third sublayer 112, comprises a nonwoven web, for example a spunlace nonwoven. By way of example, the middle substrate sublayer, i.e., third sublayer 112, can comprise wettable, regenerated cellulosic fibers such as, for example, viscose or Tencel. The middle substrate sublayer, i.e., third sublayer 112, can have a basis weight of from 2 grams per square meter (gsm) to 80 gsm, for example from 10 gsm to 30 gsm, from 17 gsm to 23 gsm, equal to 20 gsm, or equal to 30 gsm. By way of example, the middle substrate layer can utilize a web of spunlace viscose fibers have a basis weight of from 20 gsm to 80 gsm, for example 20 gsm or 30 gsm; or can utilize a web of spunbond viscose fibers having a basis weight of from 6 gsm to 40 gsm. In other embodiments, the middle substrate layer, i.e., third sublayer 112, can comprise a through-air-dried (TAD) tissue with a basis weight of from 10 gsm to 35 gsm, for example, from 15 gsm to 30 gsm, from 18 gsm to 28 gsm, or equal to 19 gsm. In yet further embodiments, the middle substrate layer, i.e., third sublayer 112, can comprise wettable TAD or resin-bonded, carded polyester nonwovens, for example, of the types typically used as acquisition distribution layers in absorbent products.

[0062] Each of the absorbent sublayers (first and second sublayers 104, 108) comprises super-absorbent polymer (SAP) particles 116 and an adhesive 120 supporting the SAP particles in a porous matrix. In addition to permitting fluid to travel through the absorbent sublayers, the porous matrix also improves the compressibility and resilience of the laminate even when the SAP particles are dry. The SAP particles in each of the absorbent sublayers (first and second sublayers 104, 108) has a basis weight of from 20 gsm to 80 gsm, for example from 35 gsm to 65 gsm, from 45 gsm to 55 gsm, or equal to 50 gsm. The adhesive in each of the absorbent sublayers (first and second sublayers 104, 108) can have a basis weight of from 0.5 gsm to 10 gsm, for example from 0.5 gsm to 5 gsm, from 1 gsm to 3 gsm, or equal to 2 gsm. The adhesive basis weight may also be expressed as a percentage of the SAP basis weight; for example, the basis weight of the adhesive may be from 2% to 6% of the basis weight of the SAP particles.

[0063] In the embodiment shown, first sublayer 104 is similar to second sublayer 108, including in SAP basis weight and thickness; however, in other embodiments, second sublayer 108 may differ from first sublayer 104 in any of various properties such as SAP basis weight, thickness, and/or the like. In one example, first sublayer 104 can have SAP basis weight of 40 gsm and an adhesive basis weight of 1.5 gsm, while second sublayer 108 can have a SAP basis weight of 60 gsm and an adhesive basis weight of 2.5 gsm. The adhesive (120) can be configured to provide adhesion while concurrently being permeable to liquids in order to allow the liquids to pass into and/or through the absorbent sublayers (first and second sublayers 104, 108). For example, the adhesive can be included in the absorbent sublayers in sufficient quantity to cause absorbent laminate 10 to exhibit minimum structural properties, for example, an elongation at break of at least 100%, for example from 600% to 1800%, to reduce gel blocking when the SAP are swollen by body fluids.

[0064] As mentioned, the SAP material can be in the form of particles 116. Exemplary superabsorbent polymer material can comprise any superabsorbent polymer particles known from superabsorbent literature, for example such as described in Modern Superabsorbent Polymer Technology, F. L. Buchholz, A. T. Graham, Wiley 1998. For example, the SAP particles may be spherical, spherical-like or irregularly shaped particles, such as sausage shaped particles, or ellipsoid shaped particles of the kind typically obtained from inverse phase suspension polymerizations. The SAP particles can also be optionally agglomerated at least to some extent to form larger irregular particles. In some embodiments, the SAP particles 116 can also have a surface modification, such as a partial or full surface coating, for example to increase the hydrophilicity of the SAP particles.

[0065] The SAP particles can comprise any of a variety of materials or combinations thereof, including organic compounds, such as cross-linked polymers. Cross-linked is a commonly understood term and refers to any approach for effectively rendering normally water-soluble materials substantially water insoluble, but swellable. Such polymers can include, for example, carboxymethylcellulose, alkali metal salts of polyacrylic acids, polyacrylamides, polyvinyl ethers, hydroxypropyl cellulose, polyvinyl morpholinone, polymers and copolymers of vinyl sulfonic acid, polyacrylates, polyacrylamides, polyvinyl pyridine and the like. Other suitable polymers include hydrolyzed acrylonitrile grafted starch, acrylic acid grafted starch, and isobutylene maleic anhydride copolymers, and mixtures thereof. Organic high-absorbency materials can include natural materials, such as agar, pectin, guar gum and peat moss. In addition to organic materials, superabsorbent materials may also include inorganic materials, such as absorbent clays and silica gels. Suitable examples of SAP include T9030, T9600, T9900, and Saviva polymers from BASF Corporation in Charlotte, N.C.; and W211, W112A, W125, S125D, QX-W1482, QX-W1486, QX-W1504, and QX-W1505 from Nippon Shokubai Co. Ltd, N.A.I.I. in Houston, Tex.; and AQUA KEEP SA50 II, SA55SX II, SA60N II, SA65S, HP500, HP500E, HP600, HP600E, and HP700E from Sumitomo Seika Chemicals Co., Ltd. in Osaka, Japan.

[0066] SAP particles 116 can have a particle size distribution in the range typical of SAP commercially used in disposable hygiene products. In some embodiments, the SAP particles have sizes between about 45 micrometers (m) and 4000 m, for example between 45 m and 2000 m, or from 100 m to 1000 m. The particle size distribution of a material in particulate form can be determined, for example, by means of dry sieve analysis (EDANA 420.02 Particle Size distribution). In some embodiments, at least 90%for example at least 95% or at least 98%of the SAP particles have a particle size diameter ranging from 45 to 850 m, for example from 100 m to 800 m or from 200 m to 500 m. Surface roughness of the present laminates pad may be reduced, in some instances greatly, when less than 2% of the mass of the SAP particles is provided by particles sized greater than 500 m. Surface roughness may also be reduced when outer layers 104, 108 comprised TAD tissue, for example TAD tissue with a basis weight of from 18 to 20 gsm.

[0067] In some embodiments, the absorbent laminate as a whole and/or the SAP particles, can have a relatively high sorption capacity, i.e., can have a centrifuge retention capacity or CRC tested in 0.9% saline of at least 20 grams of saline per gram of material (g/g), or at least 30 g/g. In some embodiments, the CRC may be as high as 45 g/g or 50 g/g.

[0068] In the embodiment shown, each of first and second sublayers 104, 108 is bonded to third sublayer 112. In other embodiments, first and second sublayers 104, 108 need not be bonded to third sublayer; for example, as an alternative to a laminate configuration, first and second sublayers may be independently formed and stacked with third sublayer 112 in the depicted configuration but without bonding, and the sublayers folded together, as discussed below with reference to FIGS. 7A and 7B, such that the folds rather than bonds maintain the relative positions of the sublayers.

[0069] FIG. 3 depicts a second embodiment 100a of an absorbent laminate. Absorbent laminate 100a is substantially similar to absorbent laminate 100, with the exception that absorbent laminate 100a includes additional outer layers. As such, the difference will primary be described here, and it should be understood that those components of laminate 100a not labeled in FIG. 3 or described here are substantially similar to the components of laminate 100. As shown in FIG. 3, laminate 100a includes a fourth sublayer 124 and a fifth sublayer 128. Fourth sublayer 124 is bonded to first sublayer 104 such that first sublayer 104 is disposed between fourth sublayer 124 and third sublayer 112, and fifth sublayer 128 is bonded to second sublayer 108 such that second sublayer 108 is disposed between fifth sublayer 128 and third sublayer 112. In this embodiment, each of the outer sublayers, i.e., fourth and fifth sublayers 124, 128, comprises tissue with sufficient porosity to permit fluid to travel through the tissue into the absorbent sublayers, for example, a creped or through-air dried tissue. The tissue can have a basis weight of from 10 gsm to 25 gsm, for example from 15 gsm to 20 gsm, or equal to 17 gsm. One example of a tissue suitable in at least some embodiments for the outer layers, i.e., fourth and fifth sublayers, is a 17-gsm 3995 Machine Creped tissue from Dunn paper. In other embodiments, each of the outer sublayers, i.e., fourth and fifth sublayers 124, 128, comprises a nonwoven. In one example of a material having the configuration of FIG. 3, first sublayer 104 comprises a spunlace nonwoven of viscose fibers with a basis weight of 20 gsm, each of second and third sublayers 108, 112 comprises 50 gsm of BASF T9900 SAP particles and 2 gsm of Savare E60W adhesive, and each of fourth and fifth sublayers 124, 128 comprises a 17 gsm 3995 machine creped tissue from Dunn paper, such that the overall laminate is highly flexible and has a basis weight of 158 gsm and is thinner than 1.5 millimeters (mm).

[0070] In some embodiments, the outer sublayers, i.e., fourth and fifth sublayers 124, 128, can comprise TAD tissue, standard tissue, spunbond synthetic nonwoven, carded synthetic nonwoven, or apertured film. For example, in one example, fourth sublayer 124 comprises a TAD tissue, fifth sublayer 128 comprises a standard tissue, and third sublayer 112 comprises a spunlace nonwoven or a TAD tissue. In yet further embodiments, laminate 10a may comprise additional inner substrate layers and SAP/adhesive layers. For example, laminate 10 can in some instances comprise two or more third sublayers 112 of spunlace or TAD tissue with a corresponding number of SAP/adhesive sublayers, similar for example to sublayers 104, 108.

[0071] In the embodiment of FIG. 3, the basis weight of SAP in sublayers 104 and 108 can be selected for a particular core configuration. For example, sublayers 104 and 108 can each include 50 gsm, 75 gsm, 100 gsm, or 150 gsm of SAP. Once the basis weight of SAP in each of sublayers 104 and 108 is known, the number of layers of laminate can then be selected to achieve a desired overall basis weight of SAP in an absorbent core. By way of example, when a total basis weight of SAP of 300 gsm is desired, three layers can be used of laminate with a total of 100 gsm SAP50 gsm of SAP in each of sublayers 104, 108; two layers can be used of a laminate with a total of 150 gsm SAP75 gsm of SAP in each of sublayers 104, 108; or one layer can be used of a laminate with a total of 300 gsm of SAP150 gsm of SAP in each of sublayers 104, 108. If instead a total basis weight of SAP of 200 gsm is desired, two layers can be used of a laminate with a total of 100 gsm SAP50 gsm of SAP in each of sublayers 104, 108; or one layer can be used of a laminate with a total of 200 gsm of SAP100 gsm of SAP in each of sublayers 104, 108. Qualitative observation of partially hydrated TIP cores suggests that the resiliency and softness decreases as the basis weight of an individual SAP layer in a laminate increases, and as the number of layers of absorbent laminate in a core decreases.

[0072] FIGS. 4A-4C depict stages of a method of manufacturing laminate 100 of FIG. 2. As shown in FIG. 4A, the process begins with the middle substrate sublayer, i.e., third sublayer 112.

[0073] As shown in FIG. 4B, first sublayer 104 is added to a first side of third sublayer 112. For example, adding first sublayer 104 can include distributing adhesive, for example by spraying, on the first side of third sublayer 112, and airlaying super-absorbent polymer (SAP) particles in contact with the adhesive on the first side of third sublayer 112 to define first sublayer 104. The adhesive on the first side of third sublayer 112 can, for example, comprise a foam. In some embodiments, the adhesive and SAP of each sublayer are applied as a mixture to the nonwoven web.

[0074] As shown in FIG. 4C, second sublayer 108 is added to a second side of third sublayer 112. For example, adding second sublayer 108 can include distributing adhesive, for example by spraying, on the second side of third sublayer 112, and airlaying super-absorbent polymer (SAP) particles in contact with the adhesive on the first side of third sublayer 112 to define second sublayer 108. The adhesive on the second side of third sublayer 112 can, for example, comprise a foam. As shown in FIG. 4C, because the SAP particles are airlaid in this embodiment, third sublayer 112 is turned over so that the second side of the third sublayer (112) is facing up to receive the adhesive and SAP particles. In some embodiments, the adhesive and SAP of each sublayer are applied as a mixture to the nonwoven web.

[0075] In the present methods of making laminate 100, the SAP particles can be conventionally mixed with hot melt adhesive fibers of the type produced by commercially available meltblown-type glue heads widely used in the manufacture of disposable absorbent articles. The hot melt adhesive can be any adhesive, for example a pressure sensitive adhesive, suitable for use in the high speed manufacture of disposable absorbent articles, with the necessary rheology to form glue fibers in the commercially available meltblown systems. In one aspect, the hot melt adhesive can be a tacky pressure sensitive synthetic rubber based adhesive, such as, for example and without limitation, Styrene-Butadiene-Styrene (SBS) or Styrene-Isoprene-Styrene (SIS) block copolymer based adhesive types. Such hot melt adhesive fibers can be added in quantities necessary to produce materials that have lamination strengths strong enough to sustain the mechanical forces applied during converting, but not excessive amounts that would interfere with the swelling of the SAP particles. In some embodiments, the adhesive has a glass transition temperature that is higher than room temperature, i.e., 73 degrees, to maintain stability while retaining flexibility. Examples of a suitable, commercially available adhesive is HB Fuller NW 1023 AAZP and Savare E60W. In some embodiments, each absorbent sublayer, i.e., first and second sublayers 104, 108, is formed by sequentially distributing adhesive, airlaying SAP particles, distributing adhesive, and airlaying SAP particles in multiple steps to build up the respective absorbent sublayer.

[0076] FIG. 4D depicts a further stage of a method of manufacturing laminate 100a of FIG. 3. As shown, the outer sublayers, i.e., fourth and fifth sublayers 124, 128, are added to the outer sides of the respective absorbent sublayers, i.e., first and second sublayers 104, 108. In some embodiments, the tissue is added and pressure applied to adhere the tissue to the respective absorbent sublayer, i.e., first or second sublayer 104, 108, before the adhesive of that sublayer is fully cooled. In other embodiments, the adhesive is distributed and SAP particles airlaid onto a respective tissue sublayer, i.e., fourth or fifth sublayer 124, 128, and the combined tissue sublayer and absorbent sublayer are subsequently positioned relative to the middle substrate layer, i.e., third sublayer 112.

[0077] Referring now to FIGS. 5 and 6; FIG. 5 depicts a perspective view of an embodiment of a core 200 utilizing an embodiment of the present absorbent laminates, for example laminate 100 or laminate 100a; and FIG. 6 depicts a side view of core 200. Core 200 includes one or more pieces of the laminate, e.g., 100 or 100a, defining a plurality of layers 204 of the absorbent laminate. For example, in the embodiment shown, a single piece of laminate 100 is folded to define an upper layer 204a, a middle layer 204b, and a lower layer 204c of the absorbent laminate. In other embodiments, multiple pieces of the absorbent laminate are stacked to define the multiple layers of the absorbent laminate, for example, with each piece defining a different layer. While the depicted embodiment includes three primary layers of the laminate, other embodiments can include any number of layers of the laminate.

[0078] In the embodiment shown in FIGS. 5 and 6, core 200 also includes an additional piece 208 of the absorbent laminate, specifically laminate 100 as shown, coupled to an upper outermost one of the sublayers of the absorbent laminate, specifically upper layer 204a. As indicated in FIG. 5, core 200i.e., layers 204a, 204b, 204c of the absorbent laminatehave a combined width W and a combined length L that is greater than the combined width and that extends from a first end 212 of core 200 to a second end 216 of core 200. In this embodiment, additional piece 208 has a length 220 that is shorter than the combined length L, and the additional piece is closer to first end 212 than to second end 216.

[0079] Core 200 can be made by stacking the plurality of layers 204a, 204b, 204c. In embodiments in which a single piece of the absorbent laminate or material defines the plurality of layers, the layers can be stacked by folding the piece of absorbent laminate over itself. For example, FIG. 7A depicts a first configuration in which the piece of absorbent laminate is folded in a C-fold configuration, and FIG. 7B depicts a second configuration in which the piece of absorbent laminate is folded in a Z-fold configuration. The multiple overlying layers of absorbent laminate defines lateral channels between layers that allow fluid to flow laterally between layers, for example, to distribute fluid over a relatively larger area of each layer for absorption. Additionally, the relative position of SAP particles 216 of adjacent layers at the interface between such layers can affect surface topography each sheet and may result in valleys and corresponding micro-channels in a relatively random distribution extending laterally to further encourage dispersion of fluid between adjacent layers of absorbent laminate. The use of highly crosslinked SAP with higher gel stiffness or SAP particles with larger particle sizes can increase the surface topography of adjacent hydrated layers and thus encourage this type of channeling.

[0080] The depicted core 200 can be used in various absorbent articles, for example underwear 10 in place of core 74, that comprise a liquid-permeable topsheet; a liquid-impermeable backsheet; and a core 200 disposed between the topsheet and the backsheet. In some such articles, the article does not include a discrete ADL in addition to the core (200). In one example of such an absorbent article, the absorbent article is a bed pad, and core 200 has a width W of at least 12 inches and a length L of at least 18 inches. In some embodiments of absorbent articles including core 200, an outer sheet with anti-microbial properties and/or a smooth or lubricated surface to reduce friction is used on the surface of the product that is in contact with the skin, for example the topsheet.

[0081] FIGS. 8A, 8B, and 8C depict alternative embodiments 200a, 200b, 200c of the present folded cores. In each these embodiments, the core includes first piece 224 of the present laminates, for example laminate 100 or laminate 100a, that is folded to define a plurality of layers, and a second piece 228 of the present laminates, for example, laminate 100 or laminate 100a, that is not folded. In core 200a, first piece 224 of the laminate is folded in a C-fold configuration in which lateral portions of the piece are folded over one another such that each of the three layers have substantially equal widths. In core 200b, first piece 224 of the laminate is folded such that lateral portions of the laminate are first folded inward in two steps to define a central channel between two separate lateral regions in which the piece defines three layers of the laminate. In this embodiment of FIG. 8B, each of the lateral regions is folded in a c-fold configuration, but in other configurations, each of the lateral regions may be folded in a Z-fold configuration. Core 200c is similar to core 200b in that that laminate is folded to define two separate lateral portions, but differs from core 200b in that each of the lateral portions is folded only once to define two layers of the laminate. In these embodiments, length 232 of first piece 224 is less than, for example, from 50% to 70% of, length 236 of second piece 228. In other embodiments, second piece 228 may be folded to define multiple layers of the laminate, or may omitted such that first piece 224 defines the entire area of the core.

[0082] Referring now to FIGS. 9A and 9B; FIG. 9A depicts compression properties of a traditional fluff/SAP core over several compression cycles after absorbing fluid; and FIG. 9B depicts compression properties of core 200 over several compression cycles after absorbing fluid. As shown in FIG. 9A, the traditional fluff/SAP core recovers only about two-thirds of its initial thickness upon release of the compressive force. In contrast, and as shown in FIG. 9B, core 200 recovers over 90 percent of its initial thickness upon release of the compressive force. A pad comprised of fluff/SAP became much stiffer after the first compression cycle. This is shown by the increase in the slope of the compression-force curve in FIG. 9A. In contrast, the TIP core in FIG. 9B remained soft over three compression cycles. The slope of a compression-force curve at a particular stress or strain, expressed as a compression modulus, is a measure of the softness of a partially hydrated core. The lack of resiliency and softness of a partially-hydrated fluff/SAP pad may be caused by a redistribution of fluff/SAP in the X-Y plane of the pad, leaving a permanent depression at the point of compression and raised ridges of material surrounding it. After repositioning of the body mass, these ridges of hard material may generate stress concentrations against skin and promote the formation of a pressure ulcer, especially in the region of a bony protuberance. In contrast, the present materials can be exhibit improved resiliency due, for example, to combinations of the SAP gel strength properties (indicated by CRC), SAP basis weight per layer, and SAP particle size distribution. In the present multi-(sub)layered laminates, the internal substrates or non-SAP sublayers can reinforce the position of SAP particles and thereby stabilize the swollen gel during compression to maintain a soft, resilient pad over repeated cycles of compression. For example, the surface texture of internal spunlace and/or TAD tissue layers can resist spreading or lateral movement of SAP particles, thereby encouraging the SAP particles to resiliently compress.

[0083] The partially-hydrated TIP core including T9900 SAP for which results are shown in FIG. 9B exhibited a strain-based softness for a second compression cycle at a strain of 10% at 0.910.sup.3 Pa when a 100 mm100 mm section of the core was dosed with 100 ml of water. The fluff/SAP core shown in FIG. 9A, which comprised about 20% SAP, had a strain-based softness of 810.sup.3 Pa. A TIP core of the same composition as that in FIG. 9B, but made with HP700E SAP, was not as soft. It had a strain-based softness on the second compression cycle of 3410.sup.3 Pa, not as good as the TIP core made with the T9900 SAP. However, the resiliency of the TIP core with P700E SAP after the first compression was 91%, nearly as good as the TIP core made with the T9900 SAP.

[0084] Referring now to FIGS. 10 and 11; FIG. 10 depicts a plan view of an embodiment 300 of a disposable patient-support pad; and FIG. 11 depicts an exploded, cross-sectional view of patient-support pad 300. In this embodiment, pad 300 comprises a support core 304 and a layer 308 coupled to the support core 304. Support core 304 is similar in some respects to core 200 in that support core 304 comprises one or more pieces of the present absorbent laminatese.g., laminate 100 or 100athat define a plurality of layers of the absorbent laminate, similar for example to layers 204a, 204b, 204c. In the embodiment shown, a single piece of the absorbent laminate can be folded to define the plurality of layers of the absorbent laminate; however, in other embodiments, multiple pieces of the absorbent laminate are stacked to define the multiple layers of the absorbent laminate, for example, with each piece defining a different layer. Additionally, like core 200, some embodiments of support core 304 further comprise an additional piece of the absorbent laminatee.g., laminate 100 or 100acoupled to an upper outermost one of the sublayers of the absorbent laminate. In the embodiment shown, in which the disposable support article is a patient-support pad such as a bed pad or seat cushion, support core 304 has a width W of at least 8 inches and a length L of at least 8 inches.

[0085] In the embodiment shown in FIGS. 10 and 11, pad 300 also includes a second layer 312 bonded to first layer 308 to define a container in which support core 304 is disposed. In this embodiment, first layer 308 can be considered a topsheet because it defines a body facing surface of the pad, and second layer 312 can be considered a backsheet because it defines an outer surface of the pad that faces away from a patient or user when the pad is used. In some configurations, first layer or topsheet 308 is treated or finished to exhibit certain properties, for example, reduced friction, increased hydrophilicity, and/or increased antimicrobial properties relative to the untreated or unfinished material of the layer. In the embodiment shown, support core 304 can be wetted with liquid to swell the SAP particles prior to placing support pad 300 under a patient. Specifically, pad 300 is configured to permit liquid to be delivered to the SAP particles prior to positioning the pad under a patient. For example, as shown in FIG. 10, the depicted embodiment of pad 300 includes a container 316, for example a rupturable bladder, disposed in the enclosure and holding a volume of liquid sufficient to, when absorbed by the SAP particles of support core 304, swell at least a portion of the SAP particles to at least a desired resiliency; and the container is configured to be ruptured to release the liquid within in the enclosure to swell the SAP particles. Such rupturable bladders can be similar, for example, to those known and used in chemical cold packs sold for first aid purposes in which a liquid is released to begin an endothermic chemical reaction and reduce the temperature of the cold pack. In other embodiments, pad 300 includes an inlet, for example a sealable inlet, through which liquid can be introduced into the enclosure. Support core can be secured to first layer 308 and/or second layer 312 by a foamed adhesive, which can add a further measure of resilience to pad 300 and can further separate the support core from the respective layer to reduce the likelihood that liquid can travel to and through the respective layer and be perceived as wetness by a user.

[0086] In the embodiment shown in FIGS. 10 and 11, both of first and second layers 304, 308 are liquid-impermeable such that pad 300 will retain liquid even under pressure due to the weight of the patient, for example to prevent the liquid from seeping through the first layer at the transdermal interface with the patient's skin. In some embodiments, topsheet 308 comprises a three-dimensional polymer film, for example a film that is also resilient, that can flex to accommodate shear forces due to compression of support core 304 in use. In other embodiments, first layer or topsheet 308 comprises a breathable material such as may be used for breathable backsheets for disposable absorbent articles. For example, first layer or topsheet 308 can include, for example, an inner liquid-impermeable film and an outer nonwoven sheet that can be a nonwoven fabric. A film is a membrane-like layer of material formed of one or more polymers, which does not have a form consisting predominately of a web-like structure of fibers and/or other fibers. In some embodiments in which first layer or topsheet 308 is breathable, for example, an inner liquid-impermeable film of layer 308 can comprise a breathable film. The terms breathable, breathable film, breathable laminate or breathable outer cover material or breathable backsheet refers to a film, laminate, or outer cover material having a water vapor transmission rate (WVTR) of at least about 300 grams/m2/24 hours. Breathable materials typically rely on molecular diffusion of vapor, and are substantially liquid impermeable. Breathability of layer 308 can permit some vapor diffusion through layer to reduce moisture build up at the transdermal interface between the patient and pad 300. In other embodiments, first layer or topsheet 308 comprises a liquid-permeable material, such as an apertured film or a hydrophilic nonwoven with sufficient porosity to acquire liquid; for example, the SAP particles in support core 304 may be wetted sufficiently to swell and impart some resilience but not so much that the SAP particles are fully saturated, and can therefore absorb additional body fluids from a patient supported by the support pad.

[0087] Some embodiments of the present patient-support pads further include a second support core 304. For example, the second support core can be disposed on top of or below the first support core in a stacked configuration, or may be laterally spaced such that the first support core is configured to be disposed under a first part of a patient, for example a first heel, and the second support core is configured to be disposed under a second part of the patient, for example a second heel. In such embodiments, the patient-support pad may define separate enclosures for the support cores or may define a single enclosure in which both support cores are disposed, for example adhered or otherwise bonded to first layer or topsheet 308.

[0088] In its simplest form, other embodiments of pad 300 can omit second layer or backsheet 312; in such a configuration, the pad can be placed with support core 308 facing a water-impermeable surface such as a solid chair surface and first layer or topsheet 308 providing a patient-facing barrier, without necessarily preventing moisture from the support core from contacting or seeping out to some degree onto the supporting surface. Such embodiments may be helpful, for example, for temporary or short-term uses in which such a cushion may be desirable, but the time of use is short enough and/or other circumstances are such that the added expense of a complete enclosure is not necessarily justified.

[0089] FIG. 12 depicts an exploded, cross-sectional view of a second configuration 300a of the patient-support pad of FIG. 10. Pad 300a is similar in several respects to pad 300, with the primary exception that pad 300a includes an absorbent core 200 in addition to support core 304, and defines two compartments for the respective cores. More particularly, pad 300a includes an intermediate layer 320 dividing the enclosure into two compartments. In this embodiment, first layer 308 comprises a liquid-permeable topsheet and intermediate layer 320 comprises a liquid-impermeable material to define a first compartment in which absorbent core 200 is disposed to receive body fluid exudates from a patient disposed on pad 300a. Intermediate sheet 320 and backsheet 312 are both liquid-impermeable to contain liquid in the compartment in which support core 304 is disposed. As with pad 300, pad 300a is configured to permit liquid to be delivered to support core 304 prior to positioning pad 300a under a patient, for example, via a container 316 or separate inlet as described above. In some embodiments, intermediate layer 320 comprises a three-dimensional polymer film, for example a film that is also resilient, that can flex to accommodate shear forces due to compression of support core 304 in use. In this embodiment, absorbent core 200 can perform the traditional absorbent functions of a conventional bed pad, while support core 300 can independently perform the support functions of a conventional patient-support cushion or seat cushion.

[0090] FIG. 13 depicts a bottom plan view of a disposable absorbent article 10a, specifically adult protective underwear, including patient-support pads 300 and in an open configuration. Underwear 10a is substantially similar to underwear 10 with the exception of patient-support pads 300, which are similar to those described above but sized for the depicted configuration. In this embodiment, patient-support pads 300 are shaped to extend around a wearer's hips to provide cushioning to distribute forces and reduce local maxima of TIP and thereby reduce the likelihood of bed sores. In other embodiments, additionally or alternatively, patient-support pads 300 can be sized and/or shaped to overlie the patient's buttocks.

[0091] In use, liquid can be delivered to the support core 304 of the patient-support pads 300 or 300a prior to placing the patient-support pads 304 under a portion of a patient, and the support core(s) allowed to absorb a sufficient volume of the liquid to increase the resilience in compression of the support core. The liquid used to swell the SAP particles can comprise water, saline, or the like; and, such liquid in some instances comprises an antimicrobial additive and/or skin care additive such as vitamin E or the like.

[0092] FIGS. 14-16 depict various views of embodiments of the present patient-support pads. More particularly, FIG. 14 depicts a top view of a patient support pad 300b that is sized and/or contoured to overlie a portion of a patient's body, for example, a hip, a shoulder, an elbow, or the head. Pad 300b is similar in constructions to pad 300 of FIG. 11, with the exception that pad 300a includes an adhesive 324 that is configured to couple the pad to a user. For example, adhesive 320 can comprise a dermal adhesive configured to adhere the pad to directly to a patient's skin, or adhesive 324 can be configured to adhere the pad to an interior surface of a patient's garment or absorbent article. FIG. 15 depicts a pad 300c that is similar in construction to pad 300b, with the exception that pad 300c is contoured to overlie a patient's sacrum or heel. FIG. 16 depicts a cross-sectional view of one optional configuration for any of pads 300, 300a, 300b, and 300c. In the configuration of FIG. 16, a support core 304a includes multiple layers of one of the present absorbent laminates, for example with the layers not bonded to one another and thereby permitted to slide relative to one another. In the depicted embodiment, the support core spans only a particular zone of the pad, for example spans less than 50% of an overall lateral dimension of the pad.

Examples

[0093] Several prototypes of the laminate depicted in FIG. 3 were produced and tested, with the materials and basis weights listed below in Table 1 below.

TABLE-US-00001 TABLE 1 Prototype Laminate Construction PROTO- PROTO- PROTO- TYPE 1 TYPE 2 TYPE 3 COMPONENT basis weight basis weight basis weight Tissue Facing (124) 17 gsm 17 gsm 17 gsm Adhesive (120) 2 gsm 2 gsm 4 gsm SAP (116) 50 gsm 56 gsm 80 gsm Nonwoven (112) 20 gsm 20 gsm 20 gsm Adhesive (120) 2 gsm 2 gsm 1 gsm SAP (116) 50 gsm 56 gsm 21 gsm Tissue Facing (128) 17 gsm 17 gsm 17 gsm ALL 158 gsm 170 gsm 160 gsm

[0094] The tissue used for the fourth sublayer 124 and fifth sublayer 128 was 17 gram per square meter (gsm) 3995 tissue from Dunn Paper. The adhesive (120) in first sublayer 104 and second sublayer 108 was E60W from Savare Specialty Adhesives. The SAP (116) in first sublayer 104 and second sublayer 108 was T9900 from BASF. The nonwoven used for sublayer 112 was a 20 gsm, 100% Viscose spunlace nonwoven from Jacob-Holm Group. Although the SAP and adhesive are separately listed, the SAP and adhesive were applied as a mixture for each sublayer 104, 108.

[0095] Each of these three prototypes were also subjected to certain tests to determine mechanical properties of their respective constructions. The results of these tests are listed in Table 2 below.

TABLE-US-00002 TABLE 2 Prototype Laminate Test Data Value: Tensile Strength Caliper (N/50 mm) (mm) Statistic (n + 3) Average s Average s PROTOTYPE 1 44.2 1.9 1.19 0.007 PROTOTYPE 2 40.3 1.4 1.23 0.015 PROTOTYPE 3 43.3 1.9 1.18 0.007

[0096] The tensile strength was measured dry in the machine direction (MD), using a Zwick Model Z005 Materials testing frame with TestXpert software. Specifically, 50 mm240 mm samples of each prototype laminate were cut and clamped into the jaws of the tensile tester with the 240 mm dimension oriented parallel to the pulling direction of the tensile tester. The jaws were then moved apart at a rate of 100 mm per minute until the sample broke or until a jaw separation of 500 mm is achieved, and the force in Newtons recorded at the point at which the sample broke or the force required to further separate the jaws dropped below 95% of the maximum force. Caliper was measured with an Emveco Electronic Microgauge Model 200 A at a pressure of 0.0725 pounds per square inch (psi).

Core Prototype & Tests

[0097] Core prototypes utilizing the above-described laminate prototypes were constructed and tested for acquisition and runoff performance. For control/comparison, traditional fluff/SAP diaper cores were subject to similar acquisition and runoff performance.

[0098] For acquisition testing, the Fluid Intake Flowback and Evaluation apparatus shown in and described with reference to FIGS. 5 and 6 of U.S. Pat. No. 5,147,343 to Kellenberger, lines 21-65 of column 10 of which patent are incorporated by reference herein. The sample core or diaper was placed on the 3-inch6-inch elevated platform according to the position described in this Kellenberger patent to center the dosing tube over the product target. An 880 g lid with 5.1 cm internal diameter (ID) dosing tube was placed on the core on alignment pins centering the dosing tube over the elevated platform.

[0099] A 100 milliliter (mL) dose of 0.9% saline (with 12 drops of McCormick Green food coloring per 20 liters of saline) was added to the dosing tube with a graduated cylinder and the time required for the liquid to drain into the core was recorded as the acquisition time. After 30-minutes, the top of the apparatus was removed and a stack of 10 Whatman No. 4, 70 mm diameter filter paper circles were placed on the center of the target of the core, and a 0.7 psi weight was placed on top of the filter paper circles for exactly 2 minutes. The filter paper circles were then removed and weighed, and the liquid absorbed by the filter papers was recorded as rewet. The doser plate was then replaced, and the above steps were repeated with a second 100 mL dose of saline. This testing was performed three times for each core prototype and diaper core, and the average and standard deviations were calculated for each core prototype or diaper core.

[0100] A core prototype was prepared by stacking two 200 mm300 mm pieces of Prototype 1 laminate (described above), and folding them longitudinally to make a 100 mm300 mm core with 4 plies of material. A piece of 15 gsm surfactant treated spunbond polypropylene diaper topsheet was placed on the top of this folded core prototype to prevent liquid from disturbing the surface of the core. A first control/comparison variant was prepared by cutting away the elastics around the perimeter of the core of size large, conventional fluff/SAP-core diapers to permit the diapers to lay flat in the apparatus. A second control/comparison variant was prepared by carefully removing the nonwoven acquisition-distribution layer (ADL) using a heat gun to separate the ADL from the topsheet of similar size large, conventional fluff/SAP-core diapers, after which the topsheet was carefully replaced over the core. All three variants were tested according to the procedure described above. The acquisition time data is recorded below Table 3 below. Particularly after the prototype core was wetted (after the first acquisition), the prototype corewithout a separate ADLexhibited acquisition times consistent with conventional diaper cores with discreet ADLs. The prototype cores also had a noticeably smaller caliper relative to the conventional cores. Specifically, the conventional fluff/SAP diaper cores had a caliper of about 5.4 mm in the target zone, whereas the prototype cores had a caliper of about 3.7 mm in the target zone.

TABLE-US-00003 TABLE 3 Acquisition Test Data statistic 1st 100 mL 2nd 100 mL (n = 3) Acquisition Acquisition Core Prototype (4 plies) average= 30.7 sec. 16.4 sec. s= 1.5 0.3 Control 1 (Large Diaper, average= 21.7 sec. 19.4 sec. with ADL) s= 0.8 2.4 Control 2 (Large Diaper, average= 39.4 sec. 38.4 sec. no ADL) s= 9.1 9.0

[0101] For acquisition testingintended to illustrate the effects of the capillary characteristics of the core to spread liquid through the core and prevent it from leaking out before SAP has time to absorba 45-degree runoff apparatus was constructed. The apparatus included a sample support surface angled at 45 degrees relative to a horizontal support surface. The sample support surface is sized to support a 150 mm100 mm core sample at a slope of 45 degrees while a dosing tube with a -inch ID is centered above the sample, with the discharge of the dosing tube disposed 25-mm above the sloping sample support surface. The 150 mm dimension of the sample is oriented along the slope, and the sample is held in place on the sample support plate by six sharp pins protruding outward from the sample support surface. The sample rests on the bottom row of pins to locate it relative to the dosing tube, and the rest of the pins puncture the sample core and thereby hold it in place along the sample support surface. In operation, dosing tube dispenses 50 ml 0.9% saline in about 6-seconds using a gravity feed from a funnel. Any of the dosed liquid that is not absorbed by the sample runs down the sample support surface to an collection trough at the bottom of the sample support surface. The collection trough is also angled to direct the liquid into a small beaker to be collected as runoff. The runoff was then poured from the beaker into a 100 ml graduated cylinder and the volume of the runoff is recorded.

[0102] Prototype cores were constructed by stacking 4150 mm100 mm plies of Prototype 1 laminate (described above). These four plies were then wrapped in a 15 gsm spunbond nonwoven diaper topsheet and the topsheet material stapled around the perimeter to prevent material of the laminate from leaking out when wetted.

[0103] For control/comparison, size large, conventional fluff/SAP-core diapers were cut transversely at a point 150 mm below the front waist of the core. Scissors were used to cut away the elastic materials from around the perimeter of the core but the side bonds retained to contain the core when wet. The core was then tucked back into the transverse cut edge and the backsheet was stapled to the topsheet to retain the core material after wetting.

[0104] Five (N=5) of each of the prototype cores and conventional diaper cores were dosed with 50 mL saline, the runoff was recorded, and then each was allowed to equilibrate 30-minutes before a subsequent dose, and the process repeated for five (5) doses. The measured runoff data is shown in Table 4 below. As shown, the prototype cores exhibited runoff comparable to that of the conventional diapers for the first dose, rather than exhibiting poorer runoff results as would typically be expected of thinnere.g., pulp-lesscores.

[0105] Given the smaller void volume of the Example 1 core, due to its thinness, it is difficult to obtain runoff values similar to that of a conventional fluff SAP diaper which is thicker.

TABLE-US-00004 TABLE 4 Runoff Test Data Statistic 1st 2nd 3rd 4th 5th (n = 5) dose dose dose dose dose Prototype Core Average = 20.2 g 7.4 g 10.8 g 15 g 19.6 g (4 plies 100 mm 150 mm) s = 1.6 1.1 1.1 1.0 1.1 Size Large Diaper Average = 18 g 20.4 g 20.6 g 28.4 g 30.2 g (150 mm core width) s = 4.2 7.6 4.8 3.4 2.3

Additional Core Prototypes and Resiliency/Softness Testing

[0106] Several prototypes of the laminate depicted in FIG. 3 were produced and tested, with the materials and basis weights listed below in Table 5 below. To investigate the effects of SAP type and middle substrate (112) materials on resiliency (recovery of thickness after compression) and softness (compression modulus, K), two different SAPs and two different middle substrates were used to make four additional prototype laminates, as listed in Table 5.

TABLE-US-00005 TABLE 5 Additional Prototype Laminate Construction PROTOTYPE 4 PROTOTYPE 5 PROTOTYPE 6 PROTOTYPE 7 COMPONENT basis weight basis weight basis weight basis weight Tissue Facing 17 gsm 17 gsm 17 gsm 17 gsm (124) Adhesive (120) 2.5 gsm 2.5 gsm 2 gsm 2.5 gsm SAP (116) 50 gsm 50 gsm 50 gsm 50 gsm BASF T9900 BASF T9900 Sumitomo Sumitomo HP700E HP700E Middle substrate 28 gsm viscose 21 gsm through- 28 gsm viscose 21 gsm through- (112) spunlace air dried tissue spunlace air dried tissue Adhesive (120) 2.5 gsm 2.5 gsm 2 gsm 2.5 gsm SAP (116) 50 gsm 50 gsm 50 gsm 50 gsm BASF T9900 BASF T9900 Sumitomo Sumitomo HP700E HP700E Tissue Facing 17 gsm 17 gsm 17 gsm 17 gsm (128)

[0107] The tissue used for the fourth sublayer 124 and fifth sublayer 128 was 17 gram per square meter (gsm) 3995 tissue from Dunn Paper. The adhesive (120) in first sublayer 104 and second sublayer 108 was E60W from Savare Specialty Adhesives. Although the SAP and adhesive are separately listed, the SAP and adhesive were applied as a mixture for each sublayer 104, 108.

[0108] From these four additional prototype laminates, four additional core prototypes were formed in the manner described above with three layers of the respective prototype laminate wrapped in a nonwoven topsheet material.

[0109] Resiliency and softness of the absorbent cores were measured using an Model 5943 Instron compression/tension apparatus equipped with a 1 kN compression/tension load cell. Test samples were constructed using a 100 mm100 mm section of an absorbent core (fluff/SAP or multiple layers of laminate) that was attached to a typical poly backsheet material with a light application of hot melt adhesive. A 12 gsm polypropylene topsheet was placed on the surface of the absorbent core. Test samples were hydrated uniformly with either 100 mL or 145 mL of tap water and equilibrated for 30 min. at 22 C./50% relative humidity before compression. After equilibration the sample was placed between two Instron compression plates (150 mm diameter) that were initially separated by a distance greater than the swollen thickness of the sample. The lower plate was rigidly attached to the base of the Instron apparatus and the upper plate was attached to a compression load cell. The samples were subjected to three successive compression/decompression cycles at a crosshead speed of 10 mm per minute. Maximum compression was set to a compressive force of either 20N or 50N. Thickness of a sample was defined as the spacing of the compression plates when compressing a sample at a force of 2 N.

[0110] The resiliency and softness relevant for an absorbent core of an absorbent product was determined by dosing a sample with 100 mL of tap water and cycling to a maximum compression force of 20N. Resiliency was defined as the % recovery in sample thickness after the first compression cycle. Higher recovery values are considered to be generally better. For example, if a sample returned to its original swollen thickness after one cycle of compression, the % recovery would be 100%. A strain-based measure of softness was defined as the compression modulus (that is, the slope of the compression force vs. strain curve expressed in Pa) at 10% compressive strain on the second compression cycle. Strain is the reduction in thickness on compression divided by the sample thickness at the beginning of a compression cycle. Smaller values of compression modulus indicate a softer core.

[0111] The resiliency and softness relevant for an absorbent core of a disposable patient-support article was determined by dosing a sample with 145 mL of tap water and cycling to a maximum compression force of either 20N or 50N. Resiliency was defined as the % recovery in sample thickness after the first compression cycle. A stress-based measure of softness was defined as the compression modulus at a maximum force of either 20 N or 50 N (i.e. at a maximum pressure of either 210.sup.3 Pa or 510.sup.3 Pa for a 100 mm100 mm sample).

[0112] Resiliency and softness was measured for four prototypes made with T9900 SAP or HP700E SAP, and middle substrates of 28 gsm viscose spunlace or 21 gsm through-air-dried tissue. Specifically, for resiliency and softness, each core was partially hydrated with 145 mL of water and then subjected to multiple applications of compressive force cycling between 2 N and 50 N over an area of 100 mm100 mm. After each compression cycle, the percentage of original thickness was measured upon removal of the compressive force. The results of these tests are listed in Table 6 below.

[0113] The hydrated thickness of prototype cores made with laminates containing T9900 SAP was between 28% and 48% greater than the hydrated thickness of prototype cores made with the HP700E SAP. The HP700E SAP had a finer particle size distribution than that of the T9900 SAP, resulting in a higher packing density for the HP700E SAP. Another difference between the SAPs is their centrifuge retention capacities or CRC, which were 33 g/g for the T9900 SAP and 47 g/g for the HP700E SAP, as determined by WSP 241.2 method.

[0114] Resiliency (i.e. Recovery of Thickness after Cycles 1, 2 & 3) for all four possible combinations of SAP and middle substrates (112) were comparable for prototype cores with three layers of absorbent laminate. Resiliency ranged from 87% to 89% for the first compression cycles and 84% to 88% for the third compression cycles. All prototype cores provided much better values of resiliency than those obtained for a fluff/SAP core. Specifically, resiliency of partially hydrated fluff/SAP cores is typically less than 70% when compressed to a pressure of between 210.sup.3 Pa (0.3 psi) and 510.sup.3 Pa (0.7 psi).

[0115] Softnessi.e., Compression Modulus at 510.sup.3 Pawas lower for the prototype cores made with the T9900 SAP. Specifically, the Compression Modulus of a partially hydrated prototype core containing T9900 SAP was 7210.sup.3 Pa at a pressure of 510.sup.3 Pa. By comparison, Softness of partially hydrated fluff/SAP cores are typically greater than 7010.sup.3 Pa at this pressure. Comparable values of softness were obtained for prototype cores made with laminates containing spunlace and tissue internal layers.

TABLE-US-00006 TABLE 6 Resiliency and Softness Data Compression Modulus, K Hydrated Recovery of Thickness (%) (10.sup.3 Pa) Thickness after after after after after after Prototype (mm) Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 4 26.3 88 88 86 47.3 71.7 75.2 5 26.9 87 85 84 41.8 72.5 75.9 6 20.6 88 87 86 61.7 124.9 132.7 7 18.2 89 88 88 74.7 146.0 156.8

[0116] The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments.

[0117] The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) means for or step for, respectively.