Unitary fluid intake system for absorbent products and methods of making same

1. A unitary fabric structure for use within a personal care absorbent article comprising:

a composite of at least two functional components for fluid intake, wherein said two functional components include a fibrous, liner functional component and at least one fibrous, surge functional component, said functional components positioned immediately adjacent one another within said composite and held together directly in facing contact with one another;

wherein said fibrous, liner functional component is comprised of hydrophilic fibers including first and second fibers, said first fibers having diameters between 10 and 18μ and a basis weight between about 4 and 6 gsm, and said second fibers having fiber diameters less than 10μ and a basis weight less than 2 gsm.

2. The unitary fabric structure of claim 1 wherein said fibrous, liner functional component is comprised of hydrophilic fibers demonstrating an advancing contact angle of between about 75 and 80°.

3. The unitary fabric structure of claim 1 , wherein said fibrous, liner functional component has a basis weight of about 6 gsm.

4. The unitary fabric structure of claim 1 , wherein said fibrous, surge functional component comprises a mixture of wettable third fibers having a size of between about 25 and 40 micron fiber diameter, and wettable fourth fibers having a size of between about 8 and 18 microns, and said third and fourth fibers demonstrating an advancing contact angle of between about 40 and 60°.

5. The unitary fabric structure of claim 4 , wherein said mixture of said third and fourth fibers includes fibers demonstrating either crimp, texture, curl, bends or combination thereof, such that said fibrous, surge functional component demonstrates a density of between about 0.03 and 0.05 g/cc.

6. The unitary fabric structure of claim 1 , wherein said composite is held together by an open bond pattern having a bond area of between about 5 and 15%.

7. The unitary fabric structure of claim 1 , wherein said composite is held together autogenously.

8. The unitary fabric structure of claim 1 , further including a fibrous, core wrap functional component positioned immediately adjacent said fibrous, surge functional component, such that said fibrous, surge functional component is sandwiched between said fibrous, liner functional component and said fibrous, core wrap functional component.

9. The unitary fabric structure of claim 8 , wherein said fibrous, core wrap functional component includes a structure that can serve as a barrier means to superabsorbent particle migration.

10. The unitary fabric structure of claim 8 , wherein said fibrous, core wrap functional component is comprised of relatively small wettable fibers having a diameter of between about 2-6 microns, and demonstrating an advancing contact angle of between about 40 and 60°.

11. The unitary fabric structure of claim 10 , wherein said fibrous, core wrap functional component includes no more than 3 gsm of 6μ or smaller dusting of fibers.

12. The unitary fabric structure of claim 1 , said fabric structure having an X, Y and Z direction, wherein said fibrous, surge functional component includes a first surge functional component and a second surge functional component, said first surge functional component including a mixture of wettable third fibers having a size from between about 25 to 40 microns diameter, and wettable fourth fibers having a size from between about 8 to 18 microns diameter, the third and fourth wettable fibers having an advancing contact angle of between about 40 and 60°, said second surge functional component including wettable fifth fibers, having a size of between about 8 to 18 microns diameter and having an advancing contact angle of between 40 and 60°.

13. An absorbent article comprising the unitary fabric structure of claim 1 , wherein said absorbent article is selected from the group consisting of feminine care hygiene articles, baby and child care articles and adult care articles.