Wet-formed composite defining latent voids and macro-cavities

Abstract

A wet-formed composite defining latent voids and macro-cavities, the wet-formed composite having a basis weight greater than about 100 grams per square meter and a density of about 0.06 grams per cubic centimeter or more. The wet-formed composite comprises fibers and superabsorbent material, with the superabsorbent material present in an amount of about 10 dry weight percent or less, specifically about 5 dry weight percent or less, and particularly about 2 dry weight percent or less, but more than 0, based on the total dry weight of fibers and superabsorbent material present in the wet-formed composite. By virtue of the superabsorbent material having been allowed to swell and then shrink during the making of the wet-formed composite, macro-cavities are created. Densification compresses the macro-cavities. The resulting composite expands upon wetting and exhibits good absorbency properties.

What is claimed is:  
     
         1 . A disposable absorbent article, comprising 
 a liquid-permeable topsheet;    a liquid-impermeable backsheet; and    an absorbent core disposed between the topsheet and the backsheet;    the absorbent core comprising a wet-formed composite which includes: 
 interbonded fibers defining a plurality of latent voids and macro-cavities between the fibers, the fibers including at least about 10% by weight resilient fibers; and  
 superabsorbent material contained by the interbonded fibers, the superabsorbent material present in an amount of less than about 5 dry weight percent, but more than 0, based on the total dry weight of the fibers and superabsorbent material.  
   
     
     
         2 . The disposable absorbent article of  claim 1 , wherein the wet-formed composite has a density of at least 0.06 grams per cubic centimeter.  
     
     
         3 . The disposable absorbent article of  claim 1 , wherein the wet-formed composite has a basis weight greater than about 100 grams per square meter.  
     
     
         4 . The disposable absorbent article of  claim 1 , wherein the resilient fibers are selected from high-yield pulp fibers, flax, milkweed, abaca, hemp, cofton, crosslinked pulp fibers, curled pulp fibers, and combinations thereof.  
     
     
         5 . The disposable absorbent article of  claim 1 , wherein the wet-formed composite includes superabsorbent material in an amount of about 2 dry weight percent or less, but more than zero, based on the total weight of superabsorbent material and fibers.  
     
     
         6 . The disposable absorbent article of  claim 1 , wherein the wet-formed composite further comprises a wet-strength additive.  
     
     
         7 . The disposable absorbent article of  claim 1 , wherein the fibers in the wet-formed composite include at least about 30% by weight resilient fibers.  
     
     
         8 . The disposable absorbent article of  claim 1 , wherein the fibers in the wet-formed composite include at least about 50% by weight resilient fibers.  
     
     
         9 . The disposable absorbent article of  claim 1 , wherein fibers in the wet-formed composite include at least about 70% by weight resilient fibers.  
     
     
         10 . A disposable absorbent article, comprising 
 a liquid-permeable topsheet;    a liquid-impermeable backsheet; and    an absorbent core disposed between the topsheet and the backsheet;    the absorbent core comprising a wet-formed composite having latent voids and macro-cavities, which includes: 
 interbonded fibers including resilient fibers and a wet strength additive; and  
 a superabsorbent material contained by the interbonded fibers;  
   the wet-formed composite having a wet:dry cohesive strength ratio of about 0.1 or greater, a dry internal cohesion value greater than about 5 kg, a cross-directional Gurley-type stiffness value less than about 500 mg, a density of about 0.06 grams per cubic centimeter or greater, and a basis weight greater than about 100 grams per square meter.    
     
     
         11 . The disposable absorbent article of  claim 10 , wherein the wet-formed composite has a wet:dry cohesive strength ratio of about 0.15 or greater.  
     
     
         12 . The disposable absorbent article of  claim 10 , wherein the wet-formed composite has a wet:dry cohesive strength ratio of about 0.30 or greater.  
     
     
         13 . The disposable absorbent article of  claim 10 , wherein the wet-formed composite has a wet:dry cohesive strength ratio of about 0.50 or greater.  
     
     
         14 . The disposable absorbent article of  claim 10 , wherein the wet-formed composite has a wet:dry cohesive strength ratio of about 0.70 or greater.  
     
     
         15 . A disposable absorbent article comprising a wet-formed composite having latent voids and macro-cavities, the wet-formed composite including: 
 interbonded fibers defining a plurality of latent voids and macro-cavities between the fibers, the fibers including at least about 10% by weight resilient fibers; and    superabsorbent material contained by the interbonded fibers, the superabsorbent material being present in an amount of less than about 5 dry weight percent, but more than zero, based on the total dry weight of the fibers and superabsorbent material.    
     
     
         16 . The disposable absorbent article of  claim 15 , comprising a feminine care article.  
     
     
         17 . The disposable absorbent article of  claim 15 , comprising a wound dressing.  
     
     
         18 . The disposable absorbent article of  claim 15 , comprising a diaper.  
     
     
         19 . The disposable absorbent article of  claim 15 , comprising an adult incontinence article.  
     
     
         20 . The disposable absorbent article of  claim 15 , wherein the resilient fibers are selected from high yield pulp fibers, flax, milkweed, abaca, hemp, cotton, crosslinked pulp fibers, curled pulp fibers, and combinations thereof.  
     
     
         21 . The disposable absorbent article of  claim 15 , wherein the wet-formed composite further comprises a wet strength additive.