Absorbent article containing unitary stratified composite

Abstract

An unitary stratified composite composed of a first stratum and a second stratum integrally connected by a transition zone is disclosed. The first stratum serves as a liquid acquisition stratum that rapidly acquires and then transfers liquid to the second stratum. The second stratum serves to withdraw liquid from the first stratum and further serves as a temporary storage stratum. Methods for forming the unitary stratified composite are also disclosed.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:  
     
         1 . An absorbent article, comprising: 
 an absorbent composite, comprising a first stratum, a second stratum, and a transition zone intermediate and coextensive with the first and second strata;    the first stratum comprising hydrophobic fibers and a binder;    the second stratum comprising a binder and fibers selected from the group consisting of hydrophilic fibers, hydrophobic fibers, and mixtures thereof; and    the transition zone comprising fibers from the first and second strata commingled substantially uniformly across the composite's width and along the composite's length.    
     
     
         2 . The absorbent article of  claim 1 , wherein the hydrophobic fibers comprise synthetic fibers.  
     
     
         3 . The absorbent article of  claim 1 , wherein the hydrophilic fibers comprise crosslinked cellulosic fibers.  
     
     
         4 . The absorbent article of  claim 1 , wherein the binder is at least one of a bicomponent fiber and a wet strength agent.  
     
     
         5 . The absorbent article of  claim 1 , wherein the article is at least one of a feminine care product, an infant diaper, and an adult incontinence product.  
     
     
         6 . An absorbent article, comprising: 
 (a) a liquid pervious topsheet;    (b) an absorbent composite, comprising a first stratum, a second stratum, and a transition zone intermediate and coextensive with the first and second strata;    the first stratum comprising hydrophobic fibers and a binder;    the second stratum comprising a binder and fibers selected from the group consisting of hydrophilic fibers, hydrophobic fibers, and mixtures thereof; and    the transition zone comprising fibers from the first and second strata commingled substantially uniformly across the composite's width and along the composite's length; and    (c) a liquid impervious backsheet.    
     
     
         7 . The absorbent article of  claim 6 , wherein the hydrophobic fibers comprise synthetic fibers.  
     
     
         8 . The absorbent article of  claim 6 , wherein the hydrophilic fibers comprise crosslinked cellulosic fibers.  
     
     
         9 . The absorbent article of  claim 6 , wherein the binder is at least one of a bicomponent fiber and a wet strength agent.  
     
     
         10 . The absorbent article of  claim 6 , wherein the article is at least one of a feminine care product, an infant diaper, and an adult incontinence product.  
     
     
         11 . An absorbent article, comprising: 
 (a) a liquid pervious topsheet;    (b) an absorbent composite, comprising a first stratum, a second stratum, and a transition zone intermediate and coextensive with the first and second strata;    the first stratum comprising hydrophobic fibers and a binder;    the second stratum comprising a binder and fibers selected from the group consisting of hydrophilic fibers, hydrophobic fibers, and mixtures thereof; and    the transition zone comprising fibers from the first and second strata commingled substantially uniformly across the composite's width and along the composite's length;    (c) a storage stratum comprising an absorbent fibrous material; and    (d) a liquid impervious backsheet.    
     
     
         12 . The absorbent article of  claim 11 , wherein the hydrophobic fibers comprise synthetic fibers.  
     
     
         13 . The absorbent article of  claim 11 , wherein the hydrophilic fibers comprise crosslinked cellulosic fibers.  
     
     
         14 . The absorbent article of  claim 11 , wherein the binder is at least one of a bicomponent fiber and a wet strength agent.  
     
     
         15 . The absorbent article of  claim 11 , wherein the article is at least one of an infant diaper and an adult incontinence product.  
     
     
         16 . An absorbent article, comprising: 
 (a) a liquid pervious topsheet;    (b) an absorbent composite, comprising a first stratum, a second stratum, and a transition zone intermediate and coextensive with the first and second strata;    the first stratum comprising hydrophobic fibers and a binder;    the second stratum comprising a binder and fibers selected from the group consisting of hydrophilic fibers, hydrophobic fibers, and mixtures thereof; and    the transition zone comprising fibers from the first and second strata commingled substantially uniformly across the composite's width and along the composite's length;    (c) a storage stratum comprising an absorbent fibrous material;    (d) an intermediate stratum interposed between the absorbent composite and the storage stratum; and    (e) a liquid impervious backsheet.    
     
     
         17 . The absorbent article of  claim 16 , wherein the hydrophobic fibers comprise synthetic fibers.  
     
     
         18 . The absorbent article of  claim 16 , wherein the hydrophilic fibers comprise crosslinked cellulosic fibers.  
     
     
         19 . The absorbent article of  claim 16 , wherein the binder is at least one of a bicomponent fiber and a wet strength agent.  
     
     
         20 . The absorbent article of  claim 16 , wherein the article is an adult incontinence product.  
     
     
         21 . The absorbent article of  claim 16 , wherein the intermediate stratum comprises a liquid pervious tissue.  
     
     
         22 . The absorbent article of  claim 16 , wherein the intermediate stratum comprises a distribution stratum.  
     
     
         23 . The absorbent article of  claim 22 , wherein the distribution stratum comprises hydrophilic fibers and a binder.  
     
     
         24 . The absorbent article of  claim 23 , wherein the hydrophilic fibers comprise crosslinked cellulosic fibers.  
     
     
         25 . The absorbent article of  claim 23 , wherein the hydrophilic fibers comprise crosslinked eucalyptus fibers.  
     
     
         26 . An absorbent article, comprising: 
 an absorbent composite, comprising a first stratum, a second stratum, and a transition zone intermediate and coextensive with the first and second strata;    the first stratum comprising first fibers and a binder;    the second stratum comprising second fibers and a binder; and    the transition zone comprising fibers from the first and second strata commingled substantially uniformly across the composite's width and along the composite's length.    
     
     
         27 . The absorbent article of  claim 26 , wherein the first fibers comprise synthetic fibers.  
     
     
         28 . The absorbent article of  claim 26 , wherein the second fibers comprise crosslinked cellulosic fibers.  
     
     
         29 . The absorbent article of  claim 26 , wherein the binder is at least one of a bicomponent fiber and a wet strength agent.  
     
     
         30 . The absorbent article of  claim 26 , wherein the article is at least one of a feminine care product, an infant diaper, and an adult incontinence product.  
     
     
         31 . An absorbent article, comprising: 
 (a) a liquid pervious topsheet;    (b) an absorbent composite, comprising a first stratum, a second stratum, and a transition zone intermediate and coextensive with the first and second strata;    the first stratum comprising first fibers and a binder;    the second stratum comprising second fibers and a binder; and    the transition zone comprising fibers from the first and second strata commingled substantially uniformly across the composite's width and along the composite's length; and    (c) a liquid impervious backsheet.    
     
     
         32 . The absorbent article of  claim 31 , wherein the first fibers comprise synthetic fibers.  
     
     
         33 . The absorbent article of  claim 31 , wherein the second fibers comprise crosslinked cellulosic fibers.  
     
     
         34 . The absorbent article of  claim 31 , wherein the binder is at least one of a bicomponent fiber and a wet strength agent.  
     
     
         35 . The absorbent article of  claim 31 , wherein the article is at least one of a feminine care product, an infant diaper, and an adult incontinence product.  
     
     
         36 . An absorbent article, comprising: 
 (a) a liquid pervious topsheet;    (b) an absorbent composite, comprising a first stratum, a second stratum, and a transition zone intermediate and coextensive with the first and second strata;    the first stratum comprising first fibers and a binder;    the second stratum comprising second fibers and a binder; and    the transition zone comprising fibers from the first and second strata commingled substantially uniformly across the composite's width and along the composite's length;    (c) a storage stratum comprising an absorbent fibrous material; and    (d) a liquid impervious backsheet.    
     
     
         37 . The absorbent article of  claim 36 , wherein the first fibers comprise synthetic fibers.  
     
     
         38 . The absorbent article of  claim 36 , wherein the second fibers comprise crosslinked cellulosic fibers.  
     
     
         39 . The absorbent article of  claim 36 , wherein the binder is at least one of a bicomponent fiber and a wet strength agent.  
     
     
         40 . The absorbent article of  claim 36 , wherein the article is at least one of an infant diaper and an adult incontinence product.  
     
     
         41 . An absorbent article, comprising: 
 (a) a liquid pervious topsheet;    (b) an absorbent composite, comprising a first stratum, a second stratum, and a transition zone intermediate and coextensive with the first and second strata;    the first stratum comprising first fibers and a binder;    the second stratum comprising second fibers and a binder; and    the transition zone comprising fibers from the first and second strata commingled substantially uniformly across the composite's width and along the composite's length;    (c) a storage stratum comprising an absorbent fibrous material;    (d) an intermediate stratum interposed between the absorbent composite and the storage stratum; and    (e) a liquid impervious backsheet.    
     
     
         42 . The absorbent article of  claim 41 , wherein the first fibers comprise synthetic fibers.  
     
     
         43 . The absorbent article of  claim 41 , wherein the second fibers comprise crosslinked cellulosic fibers.  
     
     
         44 . The absorbent article of  claim 41 , wherein the binder is at least one of a bicomponent fiber and a wet strength agent.  
     
     
         45 . The absorbent article of  claim 41 , wherein the article is an adult incontinence product.  
     
     
         46 . The absorbent article of  claim 41 , wherein the intermediate stratum comprises a liquid pervious tissue.  
     
     
         47 . The absorbent article of  claim 41 , wherein the intermediate stratum comprises a distribution stratum.  
     
     
         48 . The absorbent article of  claim 47 , wherein the distribution stratum comprises hydrophilic fibers and a binder.  
     
     
         49 . The absorbent article of  claim 48 , wherein the hydrophilic fibers comprise crosslinked cellulosic fibers.  
     
     
         50 . The absorbent article of  claim 48 , wherein the hydrophilic fibers comprise crosslinked eucalyptus fibers.  
     
     
         51 . An absorbent article, comprising: 
 an absorbent composite, comprising a first stratum, a second stratum, and a transition zone intermediate and coextensive with the first and second strata;    the first stratum comprising synthetic fibers and a binder;    the second stratum comprising crosslinked cellulosic fibers and a binder; and    the transition zone comprising fibers from the first and second strata commingled substantially uniformly across the composite's width and along the composite's length.    
     
     
         52 . The absorbent article of  claim 51 , wherein the binder is at least one of a bicomponent fiber and a wet strength agent.  
     
     
         53 . The absorbent article of  claim 51 , wherein the article is at least one of a feminine care product, an infant diaper, and an adult incontinence product.  
     
     
         54 . An absorbent article, comprising: 
 (a) a liquid pervious topsheet;    (b) an absorbent composite, comprising a first stratum, a second stratum, and a transition zone intermediate and coextensive with the first and second strata;    the first stratum comprising synthetic fibers and a binder;    the second stratum comprising crosslinked cellulosic fibers and a binder; and    the transition zone comprising fibers from the first and second strata commingled substantially uniformly across the composite's width and along the composite's length; and    (c) a liquid impervious backsheet.    
     
     
         55 . The absorbent article of  claim 54 , wherein the binder is at least one of a bicomponent fiber and a wet strength agent.  
     
     
         56 . The absorbent article of  claim 54 , wherein the article is at least one of a feminine care product, an infant diaper, and an adult incontinence product.  
     
     
         57 . An absorbent article, comprising: 
 (a) a liquid pervious topsheet;    (b) an absorbent composite, comprising a first stratum, a second stratum, and a transition zone intermediate and coextensive with the first and second strata;    the first stratum comprising synthetic fibers and a binder;    the second stratum comprising crosslinked cellulosic fibers and a binder; and    the transition zone comprising fibers from the first and second strata commingled substantially uniformly across the composite's width and along the composite's length;    (c) a storage stratum comprising an absorbent fibrous material; and    (d) a liquid impervious backsheet.    
     
     
         58 . The absorbent article of  claim 57 , wherein the binder is at least one of a bicomponent fiber and a wet strength agent.  
     
     
         59 . The absorbent article of  claim 57 , wherein the article is at least one of an infant diaper and an adult incontinence product.  
     
     
         60 . An absorbent article, comprising: 
 (a) a liquid pervious topsheet;    (b) an absorbent composite, comprising a first stratum, a second stratum, and a transition zone intermediate and coextensive with the first and second strata;    the first stratum comprising synthetic fibers and a binder;    the second stratum comprising crosslinked cellulosic fibers and a binder; and    the transition zone comprising fibers from the first and second strata commingled substantially uniformly across the composite's width and along the composite's length;    (c) a storage stratum comprising an absorbent fibrous material;    (d) an intermediate stratum interposed between the absorbent composite and the storage stratum; and    (e) a liquid impervious backsheet.    
     
     
         61 . The absorbent article of  claim 60 , wherein the binder is at least one of a bicomponent fiber and a wet strength agent.  
     
     
         62 . The absorbent article of  claim 60 , wherein the article is an adult incontinence product.  
     
     
         63 . The absorbent article of  claim 60 , wherein the intermediate stratum comprises a liquid pervious tissue.  
     
     
         64 . The absorbent article of  claim 60 , wherein the intermediate stratum comprises a distribution stratum.  
     
     
         65 . The absorbent article of  claim 64 , wherein the distribution stratum comprises hydrophilic fibers and a binder.  
     
     
         66 . The absorbent article of  claim 65 , wherein the hydrophilic fibers comprise crosslinked cellulosic fibers.  
     
     
         67 . The absorbent article of  claim 65 , wherein the hydrophilic fibers comprise crosslinked eucalyptus fibers.