Ultra-thin absorbent article
View Patent ↗The present invention generally relates to sanitary absorbent articles and in particular to disposable feminine sanitary absorbent articles that are extremely thin, highly absorbent and have superior structural integrity properties.
1. A napkin comprising:
a liquid permeable cover layer;
a liquid impermeable barrier layer;
an absorbent core arranged between the cover layer and barrier layer, the absorbent core comprising a first substrate layer and a second substrate layer, and a mixture of aggregate superabsorbent polymer and a hot melt adhesive between the first substrate layer and the second substrate layer, the hot melt adhesive having a three-dimensional lattice structure formed by a plurality of interconnected lattice segments, wherein the superabsorbent polymer is suspended within the three-dimensional lattice structure, wherein the superabsorbent polymer is present in an amount of between about 50% to about 98% by weight and the hot melt adhesive is present in an amount between about 50% to about 2% by weight, and wherein said mixture is free of fibrous material;
wherein the mixture extends continuously over a surface area of an adjacent layer in amount greater than 80% of a total surface area of the adjacent layer;
wherein the mixture has a vertical delamination strength of greater than 9 N;
wherein the first substrate layer includes a first wetlaid tissue layer;
wherein the second substrate layer includes a second wetlaid tissue layer; and
wherein said mixture is applied to the first substrate layer in an amount between 5 gsm and 150 gsm.
2. The napkin according to claim 1 , wherein the mixture has a vertical delamination strength of greater than 11 N.
3. The napkin according to claim 2 , wherein the mixtures has a vertical delamination strength of greater than 13 N.
4. The napkin according to claim 1 , wherein each of the lattice segments has a diameter in the range of about 0.02 mm to about 0.08 mm.
5. The napkin according to claim 1 , wherein the mixture extends over a surface area that is greater than 90% of a surface area of an adjacent layer.
6. The napkin according to claim 1 , wherein the mixture extends over a surface area that is 100% of a surface area of an adjacent layer.
7. The napkin according to claim 1 , wherein an entire portion of the mixture is applied in a continuous layer.
8. The napkin according to claim 1 , wherein the mixture extends over a surface area of greater than 2500 mm 2 .
9. The napkin according to claim 1 , wherein the mixture extends over a surface area in the range of about 3000 mm 2 to about 15000 mm 2 .
10. The napkin according to claim 1 , wherein the absorbent article has a thickness less than 3.0 mm.
11. The napkin according to claim 10 , wherein the absorbent article has a thickness less than 2.0 mm.
12. The napkin according to claim 11 , wherein the absorbent article has a thickness less than 1.5 mm.
13. The napkin according to claim 1 , wherein the absorbent article has a fluid penetration time of less than 40 seconds.
14. The napkin according to claim 13 , wherein the absorbent article has a fluid penetration time of less than 30 seconds.
15. The napkin according to claim 14 , wherein the absorbent article has a fluid penetration time of less than 15 seconds.
16. The napkin according to claim 1 , wherein the absorbent article has a rewet of less than 0.80 g.
17. The napkin according to claim 16 , wherein the absorbent article has a rewet of less than 0.65 g.
18. The napkin according to claim 17 , wherein the absorbent article has a rewet of less than 0.50 g.
19. The napkin according to claim 1 , wherein the absorbent article has an MCB stiffness of less than 150 g.
20. The napkin according to claim 19 , wherein the absorbent article has an MCB stiffness of less than 100 g.
21. The napkin according to claim 20 , wherein the absorbent article has an MCB stiffness of less than 50 g.
22. The napkin according to claim 1 , wherein the mixture includes 80 gsm superabsorbent and 6gsm hotmelt adhesive.
23. The napkin according to claim 1 , wherein the mixture includes 20 gsm superabsorbent and 3 gsm hotmelt adhesive.
24. A napkin comprising:
a liquid permeable cover layer;
a liquid impermeable barrier layer;
an absorbent core arranged between the cover layer and barrier layer, the absorbent core comprising a first substrate layer and a second substrate layer, and a mixture of aggregate superabsorbent polymer and a hot melt adhesive between the first substrate layer and the second substrate layer, the hot melt adhesive having a three-dimensional lattice structure formed by a plurality of interconnected lattice segments, wherein the superabsorbent polymer is suspended within the three-dimensional lattice structure, wherein the superabsorbent polymer is present in an amount between about 50% to about 98% by weight and the hot melt adhesive is present in an amount between about 50% to about 2% by weight, and wherein said mixture is free of fibrous material;
wherein the mixture extends continuously over a surface area of an adjacent layer in an amount greater than 80% of a total surface area of the adjacent layer;
wherein the article has a thickness less than 3.0 mm, a fluid penetration time less than 40seconds and a rewet less than 0.80 g;
wherein the mixture has a vertical delamination strength of greater than 9 N;
wherein the first substrate layer includes a first wetlaid tissue layer;
wherein the second substrate layer includes a second wetlaid tissue layer; and
wherein said mixture is applied to the first substrate layer in an amount between 5 gsm and 150 gsm.
25. The napkin according to claim 24 , wherein the mixture has a vertical delamination strength of greater than 11 N.
26. The napkin according to claim 25 , wherein the mixture has a vertical delamination strength of greater than 13 N.
27. The napkin according to claim 24 , wherein the mixture extends over a surface area that is greater than 90% of a surface area of the adjacent layer.
28. The napkin according to claim 27 , wherein the mixture extends over a surface area that is 100% of a surface area of the adjacent layer.
29. The napkin according to claim 24 , wherein an entire portion of the mixture is applied in a continuous layer.
30. The napkin according to claim 24 , wherein the mixture extends over a surface area of greater than 2500 mm 2 .
31. The napkin according to claim 30 , wherein the mixture extends over a surface area in the range of 3000 mm 2 to about 15000 mm 2 .
32. The napkin according to claim 24 , wherein the absorbent article has a thickness less than 2.0 mm.
33. The napkin according to claim 32 , wherein the absorbent article has a thickness less than 1.5 mm.
34. The napkin according to claim 24 , wherein the absorbent article has a fluid penetration time of less than 30 seconds.
35. The napkin according to claim 34 , wherein the absorbent article has a fluid penetration time of less than 15 seconds.
36. The napkin according to claim 24 , wherein the absorbent article has a rewet of less than 0.65 g.
37. The napkin according to claim 36 , wherein the absorbent article has a rewet of less than 0.50 g.
38. The napkin according to claim 36 , wherein the absorbent article has an MCB stiffness of less than 150 g.
39. The napkin according to claim 38 , wherein the absorbent article has an MCB stiffness of less than 100 g.
40. The napkin according to claim 39 , wherein the absorbent article has an MCB stiffness of less than 50 g.
41. The napkin according to claim 24 , wherein each of the lattice segments has a diameter in the range of 0.02 mm to about 0.08 mm.
42. The napkin according to claim 24 , wherein said mixture consists of said super absorbent polymer and said adhesive.
43. A napkin comprising:
a liquid permeable cover layer;
a liquid impermeable barrier layer;
an absorbent core arranged between the cover layer and barrier layer, the absorbent core comprising a first substrate layer and a second substrate layer, and a mixture of aggregate superabsorbent polymer and a hot melt adhesive between the first substrate layer and the second substrate layer, the hot melt adhesive having a three-dimensional lattice structure formed by a plurality of interconnected lattice segments, wherein the superabsorbent polymer is suspended within the three-dimensional lattice structure, wherein the superabsorbent polymer is present in an amount of between about 50% to about 98% by weight and the hot melt adhesive is present in an amount between about 50% to about 2% by weight, and wherein said mixture is free of fibrous material;
wherein the mixture extends continuously over a surface area of an adjacent layer in amount greater than 80% of a total surface area of the adjacent layer;
wherein the mixture consists of said super absorbent polymer and said adhesive; wherein the mixture has a vertical delamination strength of greater than 9 N;
wherein the first substrate layer includes a first wetlaid tissue layer;
wherein the second substrate layer includes a second wetlaid tissue layer; and
wherein said mixture is applied to the first substrate layer in an amount between 5 gsm and 150 gsm.
44. An absorbent core for a napkin, comprising:
a first substrate layer comprising a wetlaid tissue material;
a second substrate layer comprising a wetlaid tissue material; and
an evenly distributed mixture of aggregate superabsorbent polymer and a hot melt adhesive between the first substrate layer and the second substrate layer, the hot melt adhesive having a three-dimensional lattice structure formed by a plurality of interconnected lattice segments;
wherein the superabsorbent polymer is suspended within the three-dimensional lattice structure,
wherein the superabsorbent polymer is present in an amount of between about 50% to about 98% by weight and the hot melt adhesive is present in an amount between about 50% to about 2% by weight,
wherein the mixture is free of fibrous material,
wherein the mixture extends continuously over a surface area of an adjacent layer in amount greater than 80% of a total surface area of the adjacent layer, wherein the mixture has a vertical delamination strength of greater than 9 N, and
wherein said mixture is applied to the first substrate layer in an amount between 5 gsm and 150 gsm.