Disposable absorbent article with sealed absorbent core with substantially continuously distributed absorbent particulate polymer material

Abstract

A disposable absorbent article includes a chassis and an absorbent core which is substantially cellulose free. The chassis may contain a topsheet and a backsheet. The absorbent core may be located between the topsheet and the backsheet and may include (i) a storage layer which comprises an absorbent particulate polymer material and has a wearer facing side and an opposed garment facing side, (ii) a first core wrap sheet covering the wearer facing side of the storage layer, and (iii) a second core wrap sheet covering the garment facing side of the storage layer, the first core wrap sheet being joined to the second core wrap sheet along at least one sealing zone.

What is claimed is: 
     
         1 . A disposable absorbent article comprising:
 a chassis including a topsheet and a backsheet; and   an absorbent core, which is substantially cellulose free, located between the topsheet and the backsheet and having a wearer facing side oriented toward a wearer when the article is being worn and an opposed garment facing side, the absorbent core comprising:
 (i) a storage layer which comprises an absorbent particulate polymer material and has a wearer facing side and an opposed garment facing side, 
 (ii) a first core wrap sheet covering the wearer facing side of the storage layer, the first core wrap sheet being a first substrate for a first absorbent layer, and 
 (iii) a second core wrap sheet covering the garment facing side of the storage layer, the second core wrap sheet being a second substrate for a second absorbent layer, 
   wherein:   the first core wrap sheet is joined to the second core wrap sheet along at least one sealing zone, the sealing zone covering a total area and comprising a plurality of stripes of juncture,   the storage layer, the first core wrap sheet, and the second core wrap sheet together comprise the first and second absorbent layers, and   the absorbent particulate polymer material is disposed between the first and second substrates in an absorbent particulate polymer material area.   
     
     
         2 . The absorbent article of  claim 1  wherein the absorbent polymer material is immobilized on the first substrate and/or on the second substrate. 
     
     
         3 . The absorbent article of  claim 1  wherein the stripes of juncture extend longitudinally. 
     
     
         4 . The absorbent article of  claim 1  wherein the stripes of juncture extend transversely. 
     
     
         5 . The absorbent article of  claim 1  wherein the sealing zone comprises a transverse sealing zone. 
     
     
         6 . The absorbent article of  claim 1  wherein the sealing zone comprises a longitudinal sealing zone. 
     
     
         7 . The disposable absorbent article of  claim 1  wherein one of more of the stripes of juncture provide the sealing zone with a bond strength of at least about 1.0 N/cm. 
     
     
         8 . The absorbent article of  claim 1  wherein each stripe of juncture comprises bonding elements selected from the group of: adhesive bonds, thermo-mechanical bonds, ultrasonic bonds and combinations thereof. 
     
     
         9 . The absorbent article of  claim 8  wherein the bonding elements comprise threads of adhesives. 
     
     
         10 . The disposable absorbent article of  claim 10 , wherein the threads have a diameter from about 100 microns to about 2 millimeters. 
     
     
         11 . The absorbent article of  claim 1  wherein the sealing zone comprises an open area of at least about 20% of the total area. 
     
     
         12 . The disposable absorbent article of  claim 11 , wherein the sealing zone comprises an open area from about 30% to about 95% of the total area. 
     
     
         13 . The disposable absorbent article of  claim 1 , wherein the absorbent particulate polymer material is deposited on the first and second substrates in respective patterns of land areas and junction areas between the land areas such that the absorbent particulate polymer material is discontinuously distributed on the first and second substrates; and the first and second absorbent layers are combined together such that the respective patterns of absorbent particulate polymer material are offset from one another. 
     
     
         14 . The disposable absorbent article of  claim 13 , wherein the respective patterns are substantially the same. 
     
     
         15 . The disposable absorbent article of  claim 1 , wherein the absorbent core has a front end and a rear end and a longitudinal axis extending from the rear end to the front end and a plurality of absorbent zones, each of the plurality of absorbent zones having absorbent particulate polymer material present in differing amounts and a gradual transition in amount of absorbent particulate polymer material form one of the plurality of absorbent zones to another. 
     
     
         16 . The disposable absorbent article of  claim 1 , further comprising an acquisition system, which is located between the absorbent core and the topsheet. 
     
     
         17 . The disposable absorbent article of  claim 1 , wherein the absorbent article is a diaper comprising a re-closable fastening system joined to the chassis for securing the diaper to a wearer. 
     
     
         18 . The disposable absorbent article of  claim 1 , wherein the absorbent article is a pant-type diaper comprising at least two side panels joined to the chassis and to each other to form a pant. 
     
     
         19 . A disposable absorbent article comprising:
 a chassis including a topsheet and a backsheet; and   an absorbent core, which is substantially cellulose free, located between the topsheet and the backsheet and having a wearer facing side oriented toward a wearer when the article is being worn and an opposed garment facing side, the absorbent core comprising:
 (i) a storage layer which comprises an absorbent particulate polymer material and has a wearer facing side and an opposed garment facing side, 
 (ii) a first core wrap sheet covering the wearer facing side of the storage layer, the first core wrap sheet being a first substrate for a first absorbent layer, and 
 (iii) a second core wrap sheet covering the garment facing side of the storage layer, the second core wrap sheet being a second substrate for a second absorbent layer, 
   wherein:   the first core wrap sheet is joined to the second core wrap sheet along a transverse sealing zone and along a longitudinal sealing zone, wherein each sealing zone covers a total area and comprises at least one stripe of juncture, and at least one sealing zone comprises an open area of at least about 20% of the total area;   the storage layer, the first core wrap sheet, and the second core wrap sheet together comprise the first and second absorbent layers, and   the absorbent particulate polymer material is disposed between the first and second substrates in an absorbent particulate polymer material area.   
     
     
         20 . The disposable absorbent article of  claim 1  wherein both the longitudinal sealing zone and the transverse sealing zone comprise open areas of at least about 20% of their respective total areas.