Thin, high capacity absorbent structure and method for producing same
View Patent ↗A thin, flexible, high capacity absorbent pad and a method of making such absorbent pads. The absorbent pad contains high levels of superabsorbent material homogeneously mixed with cellulose pulp fluff. The absorbent pad is subjected to high density compaction to achieve the thinness and high absorbent capacity of the invention. The absorbent pad can be used in absorbent articles, such as diapers, training pants, feminine hygiene products, incontinence products, and swim wear.
1. An absorbent pad, comprising:
a single, densified layer including between 30 and 85 wt % superabsorbent material homogeneously mixed with between 15 and 70 wt % pulp fluff;
wherein the single-layer absorbent pad has been compacted to a density greater than about 0.28 grams per cubic centimeter and a thickness in a range of between 0.5 and 3.0 millimeters, and the single-layer absorbent pad also has an absorbent capacity between about 14 and 40 grams 0.9 w/v % saline solution per gram of absorbent pad and an edge compression between about 2726 and about 3615 gm-cm of energy to 50% compression.
2. The absorbent pad of claim 1 , wherein the absorbent pad has a density greater than about 0.30 grams per cubic centimeter.
3. The absorbent pad of claim 1 , wherein the absorbent pad has a density greater than about 0.32 grams per cubic centimeter.
4. The absorbent pad of claim 1 , wherein the absorbent pad comprises between 40 and 80 wt % superabsorbent material.
5. The absorbent pad of claim 1 , wherein the absorbent pad comprises between 50 and 75 wt % superabsorbent material.
6. The absorbent pad of claim 1 , further comprising a plurality of man-made fibers.
7. The absorbent pad of claim 1 , further comprising a plurality of carrier particles.
8. The absorbent pad of claim 1 , wherein the absorbent pad is between 0.6 and 2.5 millimeters thick.
9. The absorbent pad of claim 1 , wherein the absorbent pad is between 0.7 and 2.0 millimeters thick.
10. The absorbent pad of claim 1 , wherein the absorbent pad has an absorbent saturation capacity between 16 and 40 grams 0.9 w/v % saline solution per gram of absorbent pad.
11. The absorbent pad of claim 1 , wherein the absorbent pad has an absorbent saturation capacity between 18 and 40 grams 0.9 w/v % saline solution per gram of absorbent pad.
12. The absorbent pad of claim 1 , wherein the superabsorbent material has a gel strength of at least 0.65.
13. The absorbent pad of claim 1 , wherein the superabsorbent material has a gel strength of at least 0.75.
14. The absorbent pad of claim 1 , wherein the superabsorbent material has a gel strength of at least 0.85.
15. An absorbent article comprising the absorbent pad of claim 1 .
16. A diaper comprising the absorbent pad of claim 1 .
17. A training pant comprising the absorbent pad of claim 1 .
18. A feminine hygiene product comprising the absorbent pad of claim 1 .
19. An incontinence product comprising the absorbent pad of claim 1 .
20. A swim wear garment comprising the absorbent pad of claim 1 .
21. The absorbent pad of claim 1 , wherein the absorbent pad has a higher basis weight in a first zone than in a second zone.
22. The absorbent pad of claim 1 , further comprising a wrap material encompassing the single-layer absorbent pad.
23. The absorbent pad of claim 1 , wherein the single-layer absorbent pad is formed to a specific shape.
24. An absorbent pad, comprising:
a single, densified layer including between 30 and 85 wt % superabsorbent material; and
between 15 and 70 wt % pulp fluff
wherein the single-layer absorbent pad has been compacted to a density greater than about 0.30 grams per cubic centimeter and a thickness in a range of between 0.5 and 3.0 millimeters, and the single-layer absorbent pad also has an edge compression between about 2726 and about 3615 gm-cm of energy to 50% compression, and the superabsorbent material forms a gradient within the absorbent pad.
25. The absorbent pad of claim 24 , wherein the absorbent pad comprises between 40 and 80 wt % superabsorbent material.
26. The absorbent pad of claim 24 , wherein the absorbent pad comprises between 50 and 75 wt % superabsorbent material.
27. The absorbent pad of claim 24 , further comprising a plurality of man-made fibers.
28. The absorbent pad of claim 24 , further comprising a plurality of carrier particles.
29. The absorbent pad of claim 24 , wherein the absorbent pad is between 0.6 and 2.5 millimeters thick.
30. The absorbent pad of claim 24 , wherein the absorbent pad is between 0.7 and 2.0 millimeters thick.
31. The absorbent pad of claim 24 , wherein the absorbent pad has an absorbent saturation capacity between about 14 and 40 grams 0.9 w/v % saline solution per gram of absorbent pad.
32. The absorbent pad of claim 24 , wherein the absorbent pad has an absorbent saturation capacity of at least 16 grams 0.9 w/v % saline solution per gram of absorbent pad.
33. The absorbent pad of claim 24 , wherein the absorbent pad has an absorbent saturation capacity of at least 18 grams 0.9 w/v % saline solution per gram of absorbent pad.
34. The absorbent pad of claim 24 , wherein the superabsorbent material has a gel strength of at least 0.65.
35. The absorbent pad of claim 24 , wherein the superabsorbent material has a gel strength of at least 0.75.
36. The absorbent pad of claim 24 , wherein the superabsorbent material has a gel strength of at least 0.85.
37. The absorbent pad of claim 24 , wherein the absorbent pad includes more superabsorbent material at a first end than at a second end opposite the first end.
38. The absorbent pad of claim 24 , wherein the absorbent pad includes more superabsorbent material along a top surface than along a bottom surface.
39. The absorbent pad of claim 24 , wherein the absorbent pad includes more superabsorbent material along a bottom surface than along a top surface.
40. The absorbent pad of claim 24 , wherein a concentration of the superabsorbent material varies throughout the gradient by about 0.01 to about 0.40 grams per cubic centimeter.
41. The absorbent pad of claim 24 , wherein a concentration of the superabsorbent material varies throughout the gradient by about 0.05 to about 0.35 grams per cubic centimeter.
42. The absorbent pad of claim 24 , wherein a concentration of the superabsorbent material varies throughout the gradient by about 0.15 to about 0.25 grams per cubic centimeter.
43. The absorbent pad of claim 24 , further comprising a wrap material encompassing the single-layer absorbent pad.
44. The absorbent pad of claim 24 , wherein the single-layer absorbent pad is formed to a specific shape.