Absorbent composite having improved surface dryness
The present invention provides an absorbent composite having improved surface dryness. The composite has three strata with adjacent strata separated by a transition zone. The composite's first stratum includes synthetic fibers and provides the composite with improved surface dryness. Methods for forming the composite and absorbent articles that incorporated the composite are also provided.
1 - 107 . (canceled)
108 . An absorbent composite comprising a first stratum, a second stratum, a third stratum, a first transition zone intermediate and coextensive with the first and second strata, and a second transition zone intermediate and coextensive with the second and third strata;
the first stratum comprising at least one of synthetic fibers, matrix fibers, and resilient fibers
the second stratum comprising absorbent material and at least one of matrix fibers and resilient fibers;
the third stratum comprising at least one of synthetic fibers, matrix fibers, and resilient fibers;
the first transition zone comprising fibers from the first and second strata commingled substantially uniformly across the composite's width and along the composite's length; and
the second transition zone comprising fibers from the second and third strata commingled substantially uniformly across the composite's width and along the composite's length.
109 . The composite of claim 1 , wherein the resilient fibers comprise fibers selected from the group consisting of chemically stiffened fibers, anfractuous fibers, chemithermomechanical pulp fibers, prehydrolyzed kraft pulp fibers, synthetic fibers, crosslinked cellulosic fibers, and mixtures thereof.
110 . The composite of claim 1 , wherein the synthetic fibers comprise fibers selected from the group consisting of polyolefin, polyester, polyamide, polyethylene terephthalate and thermobondable fibers.
111 . The composite of claim 1 , wherein the matrix fibers comprise fibers selected from the group consisting of cellulosic fibers, wood pulp fibers, cotton linters, cotton fibers, hemp fibers, rayon fibers, cellulose acetate fibers, and mixtures thereof.
112 . The composite of claim 1 , wherein one or more strata further comprises a binder selected from the group consisting of thermoplastic fibers, soluble bonding mediums, bicomponent binding fibers, wet strength agents, and a poly-amide-epichlorohydrin resin.
113 . The composite of claim 1 , wherein the absorbent material comprises a superabsorbent polymer.
114 . The composite of claim 4 , wherein the wood pulp fibers are present in the first stratum in an amount from about 20 to about 80 percent by weight based on the total weight of fibers in the stratum.
115 . The composite of claim 2 , wherein the crosslinked cellulosic fibers are present in the first stratum in an amount from about 20 to about 80 percent by weight based on the total weight of fibers in the stratum.
116 . The composite of claim 1 , wherein the second stratum comprises from about 20 to about 80 percent by weight absorbent material based on the total weight of the stratum.
117 . The composite of claim 3 , wherein the polyethylene terephthalate fibers are present in the third stratum in an amount from about 70 to about 90 percent by weight based on the total weight of fibers in the stratum.
118 . The composite of claim 5 , wherein the bicomponent binding fibers are present in the third stratum in an amount from about 10 to about 30 percent by weight based on the total weight of fibers in the stratum.
119 . The composite of claim 4 , wherein the wood pulp fibers are present in any one of the second or the third stratum in an amount from about 30 to about 80 percent by weight based on the total weight of fibers in the stratum.
120 . The composite of claim 2 , wherein the crosslinked cellulosic fibers are present in any one of the second or the third stratum in an amount from about 20 to about 70 percent by weight based on the total weight of fibers in the stratum.
121 . A method for forming a fibrous web, comprising the steps of:
(a) forming a first fibrous furnish comprising fibers in an aqueous dispersion medium;
(b) forming a second fibrous furnish comprising fibers in an aqueous dispersion medium;
(c) moving a first foraminous element in a first path;
(d) moving a second foraminous element in a second path;
(e) passing the first fibrous furnish into contact with the first foraminous element moving in the first path;
(f) passing the second fibrous furnish into contact with the second foraminous element moving in the second path;
(g) passing a third fibrous furnish between the first and second furnishes; and
(h) withdrawing liquid from the first, second, and third fibrous furnishes through the first and second foraminous elements to provide a fibrous web.
122 . The method of claim 14 , wherein the first fibrous furnish comprises synthetic fibers and bicomponent binder fibers.
123 . The method of claim 14 , wherein the second fibrous furnish comprises matrix fibers, resilient fibers, absorbent material and a binder.
124 . The method of claim 14 , wherein the third fibrous furnish comprises synthetic fibers and binder fibers.
125 . The method of claim 14 , wherein the third fibrous furnish comprises matrix fibers and resilient fibers.