Absorbent structure with aggregate clusters

Abstract

An absorbent structure has a macro absorbent structure with a plurality of aggregate clusters intermixed therein. The aggregate clusters have a periphery, an interior, and thermoplastic binder fibers. The thermoplastic binder fibers have thermoplastic binder fiber ends. The thermoplastic binder fiber ends are located at the periphery of the aggregate clusters. The interior of the aggregate clusters are substantially free of thermoplastic binder fiber ends. The macro absorbent structure and the aggregate clusters may also include thermoplastic binder fibers, staple fibers, superabsorbent particles and the like. A method of making absorbent structures includes a first absorbent structure, dividing the first absorbent structure to create aggregate clusters, providing a stream of the aggregate clusters, providing polymeric fibers, merging the aggregate cluster stream and polymeric fiber stream into a single product stream, and making a second absorbent structure. The method may further include staple fibers, superabsorbent particles, and the like.

1 . An absorbent structure comprising a macro absorbent structure, the macro absorbent structure comprising a plurality of aggregate clusters intermixed within the macro absorbent structure, the aggregate clusters having a periphery and an interior and comprising thermoplastic binder fibers having thermoplastic binder fiber ends, the thermoplastic binder fiber ends being located at the periphery of the aggregate clusters, and the interior of the aggregate clusters being substantially free of thermoplastic binder fiber ends.  
     
     
         2 . The absorbent structure of  claim 1  wherein the macro absorbent structure further comprises long thermoplastic binder fibers and superabsorbent particles constrained within the thermoplastic binder fibers.  
     
     
         3 . The absorbent structure of  claim 2  wherein the aggregate clusters further comprise superabsorbent particles constrained within the thermoplastic binder fibers within the aggregate clusters.  
     
     
         4 . The absorbent structure of  claim 3  wherein the aggregate clusters further comprise staple fibers constrained within the thermoplastic binder fibers within the aggregate clusters.  
     
     
         5 . The absorbent structure of  claim 2  wherein the aggregate clusters further comprise staple fibers constrained within the thermoplastic binder fibers within the aggregate clusters.  
     
     
         6 . The absorbent structure of  claim 1  wherein the macro absorbent structure further comprises long thermoplastic binder fibers and staple fibers constrained within the long thermoplastic binder fibers.  
     
     
         7 . The absorbent structure of  claim 6  wherein the aggregate clusters further comprise superabsorbent particles constrained within the thermoplastic binder fibers within the aggregate clusters.  
     
     
         8 . The absorbent structure of  claim 7  wherein the aggregate clusters further comprise staple fibers constrained within the thermoplastic binder fibers within the aggregate clusters.  
     
     
         9 . The absorbent structure of  claim 6  wherein the aggregate clusters further comprise staple fibers constrained within the thermoplastic binder fibers within the aggregate clusters.  
     
     
         10 . The absorbent structure of  claim 1  wherein the macro absorbent structure further comprises long thermoplastic binder fibers, superabsorbent particles constrained within the long thermoplastic binder fibers, and staple fibers constrained within the long thermoplastic binder fibers.  
     
     
         11 . The absorbent structure of  claim 10  wherein the aggregate clusters further comprise superabsorbent particles constrained within the thermoplastic binder fibers within the aggregate clusters.  
     
     
         12 . The absorbent structure of  claim 11  wherein the aggregate clusters further comprise staple fibers constrained within the thermoplastic binder fibers within the aggregate clusters.  
     
     
         13 . The absorbent structure of  claim 10  wherein the aggregate clusters further comprise staple fibers constrained within the thermoplastic binder fibers within the aggregate clusters.  
     
     
         14 . The absorbent structure of claim I wherein the macro absorbent structure further comprises staple fibers and superabsorbent particles intermixed with the staple fibers.  
     
     
         15 . The absorbent structure of  claim 1  wherein the macro absorbent structure further comprises long thermoplastic binder fibers and the aggregate clusters are constrained within the long thermoplastic binder fibers.  
     
     
         16 . A stabilized absorbent structure comprising, 
 a. 5 to 50 wt % meltblown elastomeric polyolefin binder fibers having an average fiber length greater than 1 cm;    b. 1 to 50 wt % cellulose fibers constrained within the elastomeric polyolefin binder fibers;    c. 30 to 90 wt % superabsorbent particles constrained or entrapped within the polyolefin binder fibers; and    d. 1 to 50 wt % aggregate clusters each having a periphery and interior, the aggregate clusters comprising meltblown polyolefin binder fibers having meltblown polyolefin binder fiber ends, cellulose fibers constrained within the polyolefin binder fibers within the aggregate clusters, superabsorbent particles constrained or entrapped within the polyolefin binder fibers within the aggregate clusters, wherein the meltblown polyolefin binder fiber ends are located at the periphery of the aggregate clusters and the interiors of the aggregate clusters are substantially free of meltblown polyolefin binder fiber ends.    
     
     
         17 . A method of making a stabilized absorbent structure comprising; 
 a. providing a first absorbent structure comprising long thermoplastic binder fibers;    b. dividing the first absorbent structure to create aggregate clusters;    c. providing a stream of the aggregate clusters;    d. providing a stream of extruded molten polymeric fibers;    e. merging the aggregate cluster stream and polymeric fiber stream into a single product stream; and    f. collecting the single product stream on a forming surface to make a second absorbent structure.    
     
     
         18 . The method of  claim 17  further comprising, merging a stream of superabsorbent particles in the aggregate cluster stream, the polymeric fiber stream, or the single product stream.  
     
     
         19 . The method of  claim 17  further comprising, merging a stream of wood pulp fibers in the aggregate cluster stream, the polymeric fiber stream, or the single product stream.  
     
     
         20 . A disposable absorbent article produced by the method of  claim 17.