Absorbent core, articles comprising said core, and methods of making

Abstract

An absorbent core comprising substantially continuous zones of one or more high fluid distribution structures and discontinuous zones of fluid absorption structures surrounding the one or more high fluid distribution structures, wherein the one or more high fluid distribution structures are arranged to distribute fluid across the absorbent core at a speed that is faster than the speed of fluid distribution across the absorbent core by said discontinuous fluid absorption structures, and wherein said continuous zones extend along a path that is substantially parallel to at least a portion of the perimeter of the core, said portion of the perimeter of the core comprising at least a portion of the sides of the core and one of the ends of the core.

1 .- 14 . (canceled) 
     
     
         15 . A method of tri-stage fluid distribution in an absorbent article containing a core having substantially interconnected channels, the method comprising: distributing a first fluid at a first speed, distributing a second fluid at a second speed and distributing a third fluid at a third speed, said first speed being greater or equal to said second speed and said third speed being less than said first speed and less than or equal to said second speed, wherein the first fluid distribution is driven by the substantially interconnected channels, the second fluid distribution is driven by a three-dimensional absorbent material comprised within the core, and the third fluid distribution is driven by an amount of super absorbent polymer dispersed within the three-dimensional absorbent material. 
     
     
         16 . A process of making an absorbent core ( 101 ) comprising the steps of:
 i. providing a mold comprising a 3D insert therein, said 3D insert being an inverse shape of one or more substantially interconnected channels, wherein substantially the entire surface of the mold is in fluid communication with an under-pressure source except for the 3D insert;   ii. applying a first nonwoven web to said mold;   iii. applying a three-dimensional absorbent material over at least a portion of said nonwoven;   iv. applying a second nonwoven web directly or indirectly over the three-dimensional absorbent material;   v. optionally applying a bonding step to form a laminate comprising said first nonwoven, said second nonwoven and said three-dimensional absorbent material therebetween;   vi. optionally removing said laminate from the mold to form an absorbent core comprising one or more substantially interconnected channels having an inverse shape of said 3D insert; and   
       characterized in that at least for the duration of step iii the underpressure source is arranged to provide a vacuum force forcing said three-dimensional absorbent material around the 3D insert such to substantially evacuate the surface thereof from three-dimensional absorbent material and form one or more substantially interconnected channels substantially free of three-dimensional absorbent material. 
     
     
         17 . The process according to  claim 16  wherein the 3D insert has a cross-sectional shape selected from the group consisting of square, rectangular, oval, semicircular, and combinations thereof. 
     
     
         18 . The process according to  claim 16  wherein the 3D insert has the same depth throughout the perimeter thereof. 
     
     
         19 . The process according to  claim 16  wherein the 3D insert has varying depth throughout the perimeter thereof.