Absorbent composite, an absorbent article employing the same, and methods, systems, and apparatus for making the absorbent composite and/or article
An absorbent core composite is disclosed for incorporation into a disposable absorbent article. The composite includes a first material layer and a second material layer (preferably nonwoven) partially secured to the first material layer to define at least one pocket therebetween. Preferably, multiple pockets are defined, except in the case of where a generally uniform layer or bed of absorbent is preferred or better suited for the application. The pocket is said have a fixed initial volume. Further, an aggregate of absorbent particles is provided in the pocket(s) to occupy a portion of the fixed initial volume. The absorbent particles are preferably SAP particles and is characterized by a dry volume associated with a dry state and a swell volume associated with a liquid saturation state. In respect to or for the pocket, the aggregate is characterized by a collective dry volume and a collective swell volume, wherein the pocket has an initial configuration that retains the aggregate therein.
1 . A method of making an absorbent composite for incorporation into a disposable absorbent garment, said method comprising:
deforming a surface of a first sheet of a first nonwoven layer to form laterally elongatable surface discontinuities;
conveying the first sheet of the first nonwoven layer;
wherein said deforming of the surface is performed prior to said conveying said first sheet;
combining the first sheet with a second sheet of a second nonwoven layer;
positioning absorbent particles between the first and second sheets, thereby forming a composite including said first and second sheets sandwiching said absorbent particles therebetween;
wherein said positioning of the absorbent particles includes depositing the absorbent particles on said first sheet;
wherein said combining the first and second sheets includes applying the second sheet of the second nonwoven layer over the deposited absorbent particles and first sheet, thereby forming the composite including said first and second sheets sandwiching the absorbent particles therebetween;
bonding said first and second sheets to secure, at least partially, said absorbent particles therebetween;
wherein said surface discontinuities are at least partially removed in an expanded configuration such that said first sheet is at least partially laterally elongated in said expanded configuration.
2 . A method of making an absorbent composite for incorporation into a disposable absorbent garment, said method comprising:
conveying a first sheet of a first nonwoven layer;
prior to said conveying said first sheet, deforming a surface of said first sheet to form laterally elongatable surface discontinuities;
depositing absorbent particles on said first sheet;
applying a second sheet of a second nonwoven layer over the deposited absorbent particles and first sheet, thereby forming a composite including said two material layers sandwiching absorbent particles therebetween; and
bonding said first and second sheets to secure, at least partially, said absorbent particles therebetween;
wherein said deforming comprises folding one or more sections of said surface of said first sheet to form laterally elongatable folds thereon, providing folded sections in said first sheet; and wherein, after applying said second sheet, unfolding said folded sections to reveal lanes free of absorbent particles.
3 . The method of claim 1 , wherein said deforming the surface of said first sheet comprises corrugating the first sheet.
4 . The method of claim 1 , wherein, after said deforming the surface of said first sheet, the first sheet is creped.
5 . The method of claim 1 , wherein, after said deforming the surface of said first sheet, the first sheet comprises protrusions.
6 . The method of claim 1 , wherein, after said deforming the surface of said first sheet, the first sheet comprises grooves.
7 . The method of claim 1 , wherein, after said deforming the surface of said first sheet, the first sheet comprises depressions.
8 . The method of claim 1 , wherein said bonding the first and second sheets comprises forming bond sites between the first and second sheets including forming breakable bond sites and permanent bond sites.
9 . The method of claim 8 , wherein said breakable bond sites comprise adhesive bonds and said permanent bond sites comprise ultrasonic bonds.
10 . The method of claim 9 , wherein said adhesive bonds comprise water sensitive adhesive.
11 . The method of claim 9 , wherein said adhesive bonds are smaller than said permanent bonds.
12 . The method of claim 8 , wherein said bond sites are spaced apart bond sites.
13 . The method of claim 1 , wherein said bonding forms pockets between the first and second sheets, and wherein said absorbent material is positioned within said pockets.
14 . The method of claim 13 , wherein each said pocket has an initial configuration with a fixed initial volume that contains an aggregate of said absorbent material in a dry state, and wherein each pocket, in the expanded configuration, accommodates a swell volume of said aggregate associated with a liquid saturation state.
15 . The method of claim 1 , wherein said absorbent particles comprise SAP particles.
16 . The method of claim 1 , wherein said deforming the surface of said first sheet comprises riffling said first sheet.
17 . The method of claim 1 , wherein said deforming the surface of said first sheet comprises forming pleats in said first sheet.
18 . The method of claim 1 , wherein said deforming the surface of said first sheet comprises forming a plurality of folds in said first sheet.
19 . The method of claim 2 , wherein said absorbent particles comprise SAP particles.