Method of forming composite absorbent members

Abstract

A method for forming a composite absorbent member is provided that includes: a) extruding a first fibrous component through a first meltblowing die and intermingling pulp fibers with the first fibrous component to form a first admixture; b) extruding a second fibrous component through a second meltblowing die and intermingling pulp fibers with the second fibrous component to form a second admixture; and c) codepositing the first and second admixtures on a collecting surface so as to form a composite structure having a first layer and a second layer. The second layer has a higher weight percentage of pulp fibers than the first layer, and the average diameter of the pores within the second layer is smaller than the average diameter of the pores within the first layer.

What is claimed is:  
     
         1 . A method of forming a composite absorbent member, said method comprising: 
 a) extruding a first fibrous component through a first meltblowing die and intermingling pulp fibers with said first fibrous component to form a first admixture;    b) extruding a second fibrous component through a second meltblowing die and intermingling pulp fibers with said second fibrous component to form a second admixture, wherein said second admixture contains a higher weight percentage of pulp fibers than said first admixture; and    c) codepositing said first and second admixtures on a collecting surface so as to form a composite structure having a first layer and a second layer, wherein said second layer has a higher weight percentage of pulp fibers than said first layer, and wherein the average diameter of the pores within said second layer is smaller than the average diameter of the pores within said first layer.    
     
     
         2 . A method as defined in  claim 1 , wherein the weight percentage of pulp fibers within said second layer is at least about 10% greater than the weight percentage of pulp fibers present within said first layer.  
     
     
         3 . A method as defined in  claim 1 , wherein the weight percentage of pulp fibers within said second layer is at least about 25% greater than the weight percentage of pulp fibers present within said first layer.  
     
     
         4 . A method as defined in  claim 1 , wherein the average pore size within said second layer is at least about 10% smaller than the average pore size within said first layer.  
     
     
         5 . A method as defined in  claim 1 , wherein the average pore size within said second layer is at least about 25% smaller than the average pore size within said first layer.  
     
     
         6 . A method as defined in  claim 1 , wherein the average pore size within said second layer is at least about 50% smaller than the average pore size within said first layer.  
     
     
         7 . A method as defined in  claim 1 , wherein the composite absorbent member has an Edge Compression value of greater than about 100 grams.  
     
     
         8 . A method as defined in  claim 1 , wherein the composite absorbent member has an Edge Compression value of between about 150 grams to about 800 grams.  
     
     
         9 . A method as defined in  claim 1 , wherein the composite absorbent member has an Edge Compression value of between about 300 grams to about 600 grams  
     
     
         10 . A method as defined in  claim 1 , wherein the basis weight of said composite absorbent member is from about 150 grams per square meter to about 250 grams per square meter.  
     
     
         11 . A method as defined in  claim 1 , wherein the basis weight of said composite absorbent member is from about 150 grams per square meter to about 200 grams per square meter.  
     
     
         12 . A method of forming an absorbent article, said method comprising: 
 a) forming an absorbent member by a method that includes: 
 i) extruding a first fibrous component through a first meltblowing die and intermingling pulp fibers with said first fibrous component to form a first admixture;  
 ii) extruding a second fibrous component through a second meltblowing die and intermingling pulp fibers with said second fibrous component to form a second admixture, wherein said second admixture contains a higher weight percentage of pulp fibers than said first admixture; and  
 iii) codepositing said first and second admixtures on a collecting surface so as to form a composite structure having first and second layers, wherein the weight percentage of pulp fibers in said second layer is at least about 10% greater than the weight percentage of pulp fibers within said first layer, and wherein the average diameter of the pores within said second layer is smaller than the average diameter of the pores within said first layer; and  
   b) positioning said absorbent member between a liquid-permeable cover and a liquid-impermeable baffle.    
     
     
         13 . A method as defined in  claim 12 , wherein the weight percentage of pulp fibers within said second layer is at least about 25% greater than the weight percentage of pulp fibers present within said first layer.  
     
     
         14 . A method as defined in  claim 12 , wherein the average pore size within said second layer is at least about 25% smaller than the average pore size within said first layer.  
     
     
         15 . A method as defined in  claim 12 , wherein the average pore size within said second layer is at least about 50% smaller than the average pore size within said first layer.  
     
     
         16 . A method as defined in  claim 12 , wherein the composite absorbent member has an Edge Compression value of greater than about 100 grams.  
     
     
         17 . A method as defined in  claim 12 , wherein the composite absorbent member has an Edge Compression value of between about 150 grams to about 800 grams.  
     
     
         18 . A method as defined in  claim 12 , further comprising positioning an intake member adjacent to said liquid-permeable cover.  
     
     
         19 . A method as defined in  claim 18 , further comprising positioning a transfer delay member adjacent to said intake member.  
     
     
         20 . A method as defined in  claim 19 , wherein said composite absorbent member is positioned between said transfer delay member and said liquid-impermeable baffle.  
     
     
         21 . A method as defined in  claim 12 , wherein the absorbent article has a caliper less than about 15 millimeters.  
     
     
         22 . A method as defined in  claim 12 , wherein the absorbent article has a caliper less than about 5 millimeters.  
     
     
         23 . A method of forming a composite absorbent member, said method comprising: 
 a) extruding a first fibrous component through a first meltblowing die and intermingling pulp fibers with said first fibrous component to form a first admixture;    b) extruding a second fibrous component through a second meltblowing die and intermingling pulp fibers with said second fibrous component to form a second admixture;    c) extruding a third fibrous component through a third meltblowing die and intermingling pulp fibers with said third fibrous component to form a third admixture, wherein said second admixture contains a higher weight percentage of pulp fibers than said first admixture and a higher weight percentage of pulp fiber than said third admixture; and    d) codepositing said first, second, and third admixtures on a collecting surface so as to form a composite structure having a lower outer layer, an inner layer, and an upper outer layer, wherein the weight percentage of pulp fibers within said inner layer is at least about 10% greater than the weight percentage of pulp fibers within said lower outer layer and said upper outer layer, and wherein the average diameter of the pores within said inner layer is smaller than the average diameter of the pores within said lower outer layer and said upper outer layer.    
     
     
         24 . A method as defined in  claim 23 , wherein the weight percentage of pulp fibers within said inner layer is at least about 25% greater than the weight percentage of pulp fibers present within said lower outer layer and said upper outer layer.  
     
     
         25 . A method as defined in  claim 23 , wherein the average pore size within said inner layer is at least about 10% smaller than the average pore size within said first outer layer and said second outer layer.  
     
     
         26 . A method as defined in  claim 23 , wherein the average pore size within said inner layer is at least about 25% smaller than the average pore size within said first outer layer and said second outer layer.  
     
     
         27 . A method as defined in  claim 23 , wherein the average pore size within said inner layer is at least about 50% smaller than the average pore size within said first outer layer and said second outer layer.