Multi-layer absorbent cores and methods of manufacture

1 . An absorbent garment extending in a longitudinal and a lateral direction and comprising:

a bodyside liner;

an outer cover;

an absorbent body disposed between the bodyside liner and the outer cover, the absorbent body comprising:

a top facing material layer,

a bottom facing material layer,

a lofty nonwoven reinforcing material disposed between the top facing material layer and the bottom facing material layer the lofty nonwoven reinforcing material being a through-air bonded carded web (TABCW) material having a basis weight of between 15 gsm and about 60 gsm and made of polyolefin fibers,

absorbent material comprising superabsorbent material disposed between the top facing material layer and the bottom facing material layer and within the reinforcing material, the superabsorbent material being disposed in a plurality of spaced superabsorbent material lanes forming discrete first regions containing superabsorbent material and second regions being devoid of superabsorbent material, and

an acquisition material disposed between the absorbent body and the bodyside liner,

wherein a first side portion of the absorbent body and a second side portion of the absorbent body are folded onto a central portion of the absorbent body forming a folded absorbent body with a first folded portion and a second folded portion with a channel region disposed between the first folded portion and the second folded portion, and wherein the acquisition material spans across the channel region,

wherein at least one first region containing superabsorbent material and at least one second region being devoid of superabsorbent material are present in each of the first folded portion and the second folded portion.

2 . The absorbent garment of claim 1 , wherein the channel region is disposed proximate the bodyside liner.

3 . The absorbent garment of claim 1 , further comprising a first adhesive seam and a second adhesive seam, each of the first adhesive seam and the second adhesive seam bonding the top facing material layer to itself in each of the first folded portion and the second folded portion.

4 . The absorbent garment of claim 1 , wherein the acquisition material is bonded to the top facing material layer in the channel region.

5 . The absorbent garment of claim 1 , wherein the acquisition material is bonded to the absorbent body by a first lateral adhesive zone and a second lateral adhesive zone, wherein an adhesive-free zone is disposed between the first lateral adhesive zone and the second lateral adhesive zone, the adhesive-free zone overlapping the channel region.

6 . The absorbent garment of claim 1 , wherein the folded absorbent body has a lateral width, the channel region has a lateral width, and the channel region lateral width being between 40% and 60% of the folded absorbent body lateral width.

7 . The absorbent garment of claim 1 , wherein the superabsorbent material is deposited onto the reinforcing material on both a first side of the reinforcing material and a second side of the reinforcing material.

8 . The absorbent garment of claim 7 , wherein the superabsorbent material is deposited onto the first side of the reinforcing material such that it forms a plurality of spaced superabsorbent material lanes on the first side of the reinforcing material and onto the second side of the reinforcing material such that it forms a plurality of spaced superabsorbent material lanes on the second side of the reinforcing material.

9 . The absorbent garment of claim 8 , wherein the plurality of superabsorbent material lanes on the first side of the reinforcing material laterally overlap with the plurality of spaced superabsorbent material lanes on the second side of the reinforcing material.

10 . The absorbent garment of claim 9 , wherein the plurality of spaced superabsorbent material lanes on the first side of the reinforcing material have widths in the lateral direction, and wherein a total combined overlapping width of all of the lateral widths for which the plurality of spaced superabsorbent material lanes on the first side of the reinforcing material laterally overlap with the plurality of spaced superabsorbent material lanes on the second side of the reinforcing material is greater than 50% of a total combined width of the plurality of spaced superabsorbent material on the first side of the reinforcing material.

11 . The absorbent garment of claim 8 , wherein the plurality of spaced superabsorbent material lanes on the first side of the reinforcing material are spaced apart by a first set of widths, the plurality of spaced superabsorbent material lanes on the second side of the reinforcing material are spaced by a second set of widths, wherein a difference between a smallest of the first set of widths and a largest of the first set of widths is less than 150% of the smallest of the first set of widths, and wherein a difference between a smallest of the second set of widths and a largest of the second set of widths is less than 150% of the smallest of the second set of widths.

12 . The absorbent garment of claim 8 , wherein the absorbent body has a first height as measured at a location containing a superabsorbent material lane and has a second height as measured at a location between superabsorbent material lanes, and wherein the first height is between 20% and 80% greater than the second height.

13 . The absorbent garment of claim 1 , wherein the absorbent body is substantially devoid of absorbent material within 10 mm of end edges of the absorbent body.

14 . An absorbent garment extending in a longitudinal and a lateral direction and comprising:

a bodyside liner;

an outer cover;

an absorbent body disposed between the bodyside liner and the outer cover, the absorbent body comprising:

a top facing material layer,

a bottom facing material layer,

a lofty nonwoven reinforcing material disposed between the top facing material layer and the bottom facing material layer the lofty nonwoven material being a through-air bonded carded web (TABCW) material having a basis weight of between 15 gsm and about 60 gsm and made of polyolefin fibers,

absorbent material comprising superabsorbent material forming a plurality of spaced superabsorbent material lanes disposed between the top facing material layer and the bottom facing material layer and within the reinforcing material,

wherein a first side portion of the absorbent body and a second side portion of the absorbent body are folded onto a central portion of the absorbent body forming a folded absorbent body with a first folded portion and a second folded portion with a channel region disposed between the first folded portion and the second folded portion and wherein there is no overlap between superabsorbent lanes in the first folded portion or the second folded portion, and

wherein the superabsorbent material lanes spaced from apart by a of distance between 5 mm and 15 mm and a combined width of the superabsorbent material lanes comprises between 40% and 60% of an overall width of the folded absorbent body; and

an acquisition material disposed between the absorbent body and the bodyside liner, wherein the acquisition material spans across the channel region and is bonded into the channel.

15 . The absorbent garment of claim 14 , wherein the acquisition material is bonded to the top facing material layer in the channel region.

16 . The absorbent garment of claim 14 , wherein the plurality of spaced superabsorbent material lanes on the first side of the reinforcing material laterally overlap with the plurality of spaced superabsorbent material lanes on the second side of the reinforcing material.

17 . The absorbent garment of claim 14 , wherein regions disposed between the plurality of spaced superabsorbent material lanes are substantially devoid of superabsorbent material.

18 . A method of forming an absorbent garment, the method comprising:

moving a first facing material in a machine direction;

moving a reinforcing material in the machine direction, the reinforcing material having a first side and a second side, the reinforcing material being a through-air bonded carded web (TABCW) material having a basis weight of between 15 gsm and about 60 gsm and made of polyolefin fibers;

applying superabsorbent material to the first side of the reinforcing material, the first side of the reinforcing material facing up in a vertical direction, the superabsorbent material being applied in a first series of spaced apart lanes;

reversing an orientation of the reinforcing material so that the first side of the reinforcing material faces down in the vertical direction;

applying the first side of the reinforcing material to the first facing material;

applying superabsorbent material to the second side of the reinforcing material, the superabsorbent material being applied in a second series of spaced apart lanes, wherein the first series of spaced apart lanes and the second series of spaced apart lanes overlap to form regions within the reinforcing material containing superabsorbent material and regions in the reinforcing material devoid of superabsorbent material;

moving a second facing material in the machine direction;

applying the second facing material to the second side of the reinforcing material to form an absorbent laminate comprising the first facing material, the reinforcing material, and the second facing material;

folding a first side portion and a second side portion of the absorbent laminate onto a central portion of the absorbent laminate, the first side portion and the second side portion folded onto the central portion to form a channel region in the folded absorbent laminate, wherein there is no overlap between regions containing superabsorbent material in the first side portion and the central portion and no overlap between regions containing superabsorbent material in the second side portion and the central portion;

moving an acquisition material in the machine direction;

coupling the acquisition material to the folded absorbent laminate such that the acquisition material spans across the channel region;

coupling the folded absorbent laminate and the acquisition material between a bodyside liner material and an outer cover material to form an absorbent garment.

19 . The method of claim 18 , further comprising bonding the absorbent laminate with heat, pressure, and/or ultrasonic energy to form end edges of the absorbent laminate.