ABSORBENT CORE FOR AN ABSORBENT ARTICLE

Abstract

An absorbent core for an absorbent article is provided an absorbent material, the absorbent core comprising one or more first zones comprising a first amount of absorbent material and one or more second zones comprising a second amount of absorbent material, wherein each second zone is at least partly delimited from the other second zones by the one or more first zones characterized in that the first amount of bulk absorbent material is different than the second amount of absorbent material, each amount of absorbent material being determined as weight per unit area.

Claims

1. An absorbent core for an absorbent article comprising an absorbent material, the absorbent core comprising one or more first zones comprising a first amount of absorbent material and one or more second zones comprising a second amount of absorbent material, wherein each second zone is at least partly delimited from the other second zones by the one or more first zones characterized in that the first amount of absorbent material is different than the second amount of absorbent material, each amount of absorbent material being determined as weight per unit area, wherein the one or more second zones form a pattern which is symmetrical with respect to a central longitudinal axis of the absorbent core, wherein the absorbent core comprises two end portions and a central portion therebetween extending parallel to the central longitudinal axis of the absorbent core, and wherein at least two second zones converge to one point proximal to at least one end portion such to form at least one v-shaped end.

2. An absorbent core for an absorbent article comprising an absorbent material, the absorbent core comprising one or more first zones comprising a first amount of absorbent material and one or more second zones comprising a second amount of absorbent material, wherein each second zone is at least partly delimited from the other second zones by the one or more first zones characterized in that the first amount of absorbent material is different than the second amount of absorbent material, each amount of absorbent material being determined as weight per unit area, wherein the one or more second zones form a pattern which is symmetrical with respect to a central longitudinal axis of the absorbent core, wherein the absorbent core comprises two end portions and a central portion therebetween extending parallel to the central longitudinal axis of the absorbent core, and wherein at least two second zones cross each other at a point of the central portion of the absorbent core.

3. The absorbent core according to claim 1 wherein at least two second zones cross each other at a point of the central portion of the absorbent core.

4. The absorbent core according to claim 1 wherein the ratio of the second amount of absorbent material within a second zone to the first amount of absorbent material within neighbouring one or more first zones is between 0 and 1.

5. The absorbent core according claim 1 wherein the absorbent material of the one or more second zones has a second density which is lower than a first density of the absorbent material of the one or more first zones.

6. The absorbent core according to claim 1 wherein the one or more second zones are in the form of one or more continuous or discontinuous lines.

7. The absorbent core according to claim 1 wherein at least two second zones extend along and substantially parallel to said central longitudinal axis at opposing and distal sides thereof.

8. The absorbent core according to claim 1 wherein at least two second zones converge to one point proximal to both said end portions such to form two v-shaped ends.

9. The absorbent core according to claim 1 wherein at least two second zones run parallel along said central portion and further converge to one point proximal to at least one said end portions such to form one or two v-shaped ends, wherein the at least two second zones are interconnected by one or more further second zones, and/or one or more third zones comprising a third amount of absorbent material, the third amount of absorbent material being different from the first amount of absorbent material and/or second amount of absorbent material, the one or more further second zones and/or one or more third zones extending along the central transverse axis.

10. The absorbent core according to claim 1 wherein the one or more second zones are in the form of channels, folding-lines, or combinations thereof.

11. An absorbent article selected from the group consisting of diapers, adult incontinence briefs, training pants, diaper holders, liners, sanitary napkins, surgical bandages, sponges, and combinations thereof, comprising an absorbent core according to claim 1.

12. An absorbent article selected from the group consisting of diapers, adult incontinence briefs, training pants, diaper holders, liners, sanitary napkins, surgical bandages, sponges, and combinations thereof, comprising an absorbent core according to claim 2.

13. A process for providing an absorbent core according to claim 1, for an absorbent article, the process comprising the steps of: i. providing a mould cavity comprising a shaping profile member, ii. inserting one or more absorbent materials into the mould cavity comprising the shaping profile member to form a moulded absorbent material deposit structure, iii. removing the moulded absorbent material deposit structure from the mould cavity to form an absorbent core comprising one or more first zones comprising a first amount of absorbent material and one or more second zones comprising a second amount of absorbent material, wherein each second zone is at least partly delimited by said one or more first zones said second zones having the inverse shape of the shaping profile member and wherein said first and second amounts of absorbent material, each measured as a weight per unit area, are different.

14. The process according to claim 13 comprising the steps of i. providing the mould cavity with an air permeable base surface, ii. applying a first air permeable material layer into the mould cavity comprising the shaping profile member prior to the process step of inserting the one or more absorbent materials into the mould cavity; and/or iii. applying a second material layer directly or indirectly over the one or more absorbent materials after the process step of inserting one or more absorbent materials into the mould cavity, iv. optionally applying a bonding step to form a laminate comprising the first air permeable material layer, the second material layer and the one or more absorbent materials therebetween, v. wherein in the process step ii. a pressure difference is arranged over the air permeable base surface of the mould cavity to cause the one or more absorbent materials to displace relative to the shaping profile member and to form one or more first zones comprising a first amount of absorbent material and one or more second zones comprising a second amount of absorbent material.

15. The process according to claim 13 wherein the mould cavity has an air permeable base surface, wherein the shaping profile member is a three-dimensional structure wherein in the process step ii. a pressure difference is arranged over the air permeable base surface of the mould cavity to cause the one or more absorbent materials to displace relative to the shaping profile member and to form one or more first zones comprising a first amount of absorbent material and one or more second zones comprising a second amount of absorbent material, and wherein the shaping profile member is not in fluid communication with the pressure difference arranged over the air permeable base surface of the mould cavity.

16-18. (canceled)

19. The process according to claim 13 the mould is 3D-printed as one single part comprising said shaping profile member.

20. The absorbent core according to claim 2 wherein the ratio of the second amount of absorbent material within a second zone to the first amount of absorbent material within neighbouring one or more first zones is between 0 and 1.

21. The absorbent core according to claim 2 wherein the absorbent material of the one or more second zones has a second density which is lower than a first density of the absorbent material of the one or more first zones.

22. The absorbent core according to claim 2 wherein the one or more second zones are in the form of one or more continuous or discontinuous lines.

23. The absorbent core according to claim 2 wherein at least two second zones extend along and substantially parallel to said central longitudinal axis at opposing and distal sides thereof.

24. The absorbent core according to claim 2 wherein at least two second zones converge to one point proximal to both said end portions such to form two v-shaped ends.

25. The absorbent core according to claim 2 wherein the one or more second zones are in the form of channels, folding-lines, or combinations thereof.

26. A process for providing an absorbent core according to claim 2, for an absorbent article, the process comprising the steps of: i. providing a mould cavity comprising a shaping profile member, ii. inserting one or more absorbent materials into the mould cavity comprising the shaping profile member to form a moulded absorbent material deposit structure, iii. removing the moulded absorbent material deposit structure from the mould cavity to form an absorbent core comprising one or more first zones comprising a first amount of absorbent material and one or more second zones comprising a second amount of absorbent material, wherein each second zone is at least partly delimited by said one or more first zones said second zones having the inverse shape of the shaping profile member and wherein said first and second amounts of absorbent material, each measured as a weight per unit area, are different.

27. The process according to claim 26 wherein the mould cavity has an air permeable base surface, wherein the shaping profile member is a three-dimensional structure, wherein in the process step ii. a pressure difference is arranged over the air permeable base surface of the mould cavity to cause the one or more absorbent materials to displace relative to the shaping profile member and to form one or more first zones comprising a first amount of absorbent material and one or more second zones comprising a second amount of absorbent material, and wherein the shaping profile member is not in fluid communication with the pressure difference arranged over the air permeable base surface of the mould cavity.

Description

EXAMPLE(S)

[0169] Four samples (Ultra Night size) are made, sample A with no inserts, samples B to D with insert types 1 to 3 as illustrated in FIG. 3a to 3c (all other features remaining equal).

[0170] The acquisition time (AQ) is measured for each of the samples according to the acquisition time method as defined by SGS Courtray Laboratories and table 1 and FIG. 4 illustrate the results.

TABLE-US-00001 TABLE 1 Acquisition time of examples A to D Sample A B C D Insert none FIG. 3a FIG. 3b FIG. 3c Acquisition T1 [s] 97.5 76 77.5 80.5 Time (without T2 [s] 277.5 175.5 228.5 212 pressure) T3 [s] 446 303.5 371 324 dose: 3 10 cm.sup.3 AQ time [s] = 821 555 677 617 T1 + T2 + T3

[0171] As evidenced by these results, the presence of second zones having a lower amount of absorbent material reduce the acquisition time (samples B,C,D vs. sample A). The presence of a v-shaped end as described herein (sample C) and/or the presence of a cross design in the central portion of the absorbent core as described herein (sample B) further reduce the acquisition time.

[0172] The peak bending stiffness of samples B, C, D is measured and FIG. 7 illustrate the results of flexure resistance, lower results showing improved body fit. All samples show low flexure resistance, so good comfort. The presence of a v-shaped end as described herein (sample C) and/or the presence of a cross design in the central portion of the absorbent core as described herein (sample B) further reduce the flexure resistance and further improve body fit.

[0173] Five other samples (Ultra Super size) are made, sample E with no inserts, samples F to I with insert types 1 to 3 as illustrated in FIG. 3a to 3c, and insert 61 as illustrated in FIG. 6a (all other features remaining equal).

[0174] The acquisition time (AQ) is measured for each of the samples according to the acquisition time method as defined by SGS Courtray Laboratories and table 2 illustrates the results. The peak bending stiffness of samples E to I is measured and results are also shown in Table 2.

TABLE-US-00002 TABLE 2 Acquisition time and peak bending stiffness of examples E to I Sample E F G H I Insert none FIG. 3a FIG. 3b FIG. 3c FIG. 6a Acquisition T1 [s] 49.5 46.5 46.5 54 45.5 Time T2 [s] 98 85 91.5 91 82.5 (without T3 [s] 151.5 126.5 162.5 145.5 141.5 pressure) Dose: AQ time 299 258 301 291 270 3 7 cm.sup.3 [s] = T1 + T2 + T3 Peak [N] 4.95 3.47 4.5 3.91 3.14 bending stiffness

[0175] Although samples A to D cannot be compared with samples E to I (different size, different dose, different ADL, . . . ), samples E to I can be compared, as only the insert changes. As evidenced by these results, the presence of second zones having a lower amount of absorbent material generally reduce the acquisition time and improves body fit.

[0176] Sample I, in particular, shows an excellent combination of low acquisition time (low total acquisition time and lowest T1) and lowest stiffness.