HIGH PERFORMANCE NONWOVEN STRUCTURE
The presently disclosed subject matter relates to multi-layer nonwoven materials and their use in absorbent articles. More particularly, the presently disclosed subject matter relates to layered structures that have high absorbency performance while having less absorbent mass than other commercially available materials.
1 .- 20 . (canceled)
21 . A multi-layer nonwoven acquisition material, comprising:
a first outer layer comprising synthetic fibers and having a basis weight of from about 10 gsm to about 50 gsm; and
a second outer layer comprising cellulose fibers and having a basis weight of from about 10 gsm to about 100 gsm;
wherein the multi-layer nonwoven acquisition material has a caliper from about 0.5 mm to about 4 mm and a basis weight of from about 10 gsm to about 200 gsm
22 . The multi-layer nonwoven acquisition material of claim 21 , wherein the second outer layer further comprises a binder.
23 . The multi-layer nonwoven acquisition material of claim 21 , wherein the synthetic fibers comprise polyethylene terephthalate fibers.
24 . The multi-layer nonwoven acquisition material of claim 21 , wherein the synthetic fibers comprise bicomponent fibers.
25 . The multi-layer nonwoven acquisition material of claim 21 , wherein the second outer layer comprises cellulose tissue.
26 . The multi-layer nonwoven acquisition material of claim 21 , further comprising a first intermediate layer, adjacent to the first outer layer, comprising bicomponent fibers.
27 . The multi-layer nonwoven acquisition material of claim 26 , further comprising a second intermediate layer, adjacent to the first intermediate layer, comprising bicomponent fibers.
28 . The multi-layer nonwoven acquisition material of claim 27 , wherein the second intermediate layer further comprises cellulose fibers.
29 . The multi-layer nonwoven acquisition material of claim 21 , wherein multi-layer nonwoven acquisition material has a tensile strength at peak load of greater than about 400 G/in.
30 . A multi-layer nonwoven material, comprising:
the multi-layer nonwoven acquisition material of claim 21 ; and
an absorbent core;
wherein the multi-layer nonwoven material has a caliper from about 1 mm to about 8 mm and a basis weight of from about 100 gsm to about 600 gsm.
31 . The multi-layer nonwoven material of claim 30 , wherein the absorbent core comprises:
a first layer comprising cellulose fibers;
a second layer, adjacent to the first layer, comprising SAP;
a third layer, adjacent to the second layer, comprising cellulose fibers;
a fourth layer, adjacent to the third layer, comprising SAP; and
a fifth layer, adjacent to the fourth layer, comprising cellulose fibers.
32 . The multi-layer nonwoven material of claim 31 , wherein at least one of the first layer, third layer, and fifth layer further comprise bicomponent fibers.
33 . An absorbent composite comprising the multi-layer nonwoven acquisition material of claim 21 .
34 . A multi-layer nonwoven acquisition material, comprising:
a first outer layer comprising synthetic fibers and having a basis weight of from about 10 gsm to about 50 gsm;
a first intermediate layer, adjacent to the first outer layer, comprising bicomponent fibers;
a second intermediate layer, adjacent to the first intermediate layer, comprising cellulose fibers and bicomponent fibers; and
a second outer layer, adjacent to the second intermediate layer, comprising cellulose fibers and a binder and having a basis weight of from about 10 gsm to about 100 gsm;
wherein the multi-layer nonwoven acquisition material has a caliper of from about 0.5 mm to about 4 mm and a basis weight of from about 10 gsm to about 200 gsm.
35 . A multi-layer nonwoven acquisition material, comprising:
a first outer layer comprising bicomponent fibers and having a basis weight of from about 10 gsm to about 50 gsm;
a first intermediate layer, adjacent to the first outer layer, comprising bicomponent fibers; and
a second intermediate layer, adjacent to the first intermediate layer, comprising bicomponent fibers; and
a second outer layer, adjacent to the second intermediate layer, comprising cellulose fibers and a binder and having a basis weight of from about 10 gsm to about 100 gsm;
wherein the multi-layer nonwoven acquisition material has a caliper of from about 0.5 mm to about 4 mm and a basis weight of from about 10 gsm to about 200 gsm.
36 . A multi-layer nonwoven acquisition material, comprising:
a first outer layer comprising synthetic fibers and having a basis weight of from about 10 gsm to about 50 gsm; and
a second outer layer comprising synthetic filaments;
wherein the multi-layer nonwoven acquisition material has a caliper from about 0.5 mm to about 4 mm and a basis weight of from about 10 gsm to about 200 gsm.
37 . The multi-layer nonwoven acquisition material of claim 36 , wherein the first outer layer further comprises a binder.
38 . The multi-layer nonwoven acquisition material of claim 36 , wherein the synthetic fibers comprise bicomponent fibers.
39 . The multi-layer nonwoven acquisition material of claim 36 , further comprising a first intermediate layer, adjacent to the first outer layer, comprising bicomponent fibers.
40 . The multi-layer nonwoven acquisition material of claim 39 , further comprising a second intermediate layer, adjacent to the first intermediate layer, comprising bicomponent fibers.
41 . The multi-layer nonwoven acquisition material of claim 36 , wherein multi-layer nonwoven acquisition material has a tensile strength at peak load of greater than about 400 G/in.
42 . A multi-layer nonwoven material, comprising:
the multi-layer nonwoven acquisition material of claim 36 ; and
an absorbent core;
wherein the multi-layer nonwoven material has a caliper from about 1 mm to about 8 mm and a basis weight of from about 100 gsm to about 600 gsm.
43 . The multi-layer nonwoven material of claim 42 , wherein the absorbent core comprises:
a first layer comprising cellulose fibers;
a second layer, adjacent to the first layer, comprising SAP;
a third layer, adjacent to the second layer, comprising cellulose fibers;
a fourth layer, adjacent to the third layer, comprising SAP; and
a fifth layer, adjacent to the fourth layer, comprising cellulose fibers.
44 . The multi-layer nonwoven material of claim 43 , wherein at least one of the first layer, third layer, and fifth layer further comprise bicomponent fibers.
45 . An absorbent composite comprising the multi-layer nonwoven acquisition material of claim 36 .