Structures Comprising Particles and Processes for Making Same

Abstract

Structures, for example fibrous structures, such as absorbent material, for example absorbent core material including particles, for example super absorbent polymer particles (SAP particles), and processes for making same are provided.

What is claimed is: 
     
         1 . A process for forming a composite fluid stream, the process comprising the step of mixing a first fluid stream comprising a plurality of fibrous elements with a second fluid stream comprising a plurality of first particles such that a composite fluid stream exhibiting a non-random arrangement of the plurality of first particles in the composite fluid stream is formed. 
     
     
         2 . The process according to  claim 1  wherein the plurality of fibrous elements comprises a plurality of filaments. 
     
     
         3 . The process according to  claim 1  wherein the plurality of fibrous elements comprises a plurality of filaments and a plurality of fibers. 
     
     
         4 . The process according to  claim 3  wherein the plurality of filaments and the plurality of fibers are commingled. 
     
     
         5 . The process according to  claim 1  wherein the step of mixing a first fluid stream comprising a plurality of fibrous elements with a second fluid stream comprising a plurality of first particles occurs within an enclosure. 
     
     
         6 . The process according to  claim 1  wherein the step of mixing a first fluid stream comprising a plurality of fibrous elements with a second fluid stream comprising a plurality of first particles comprises coforming the plurality of fibrous elements with the plurality of first particles. 
     
     
         7 . The process according to  claim 1  wherein the plurality of first particles exhibit a range of Stokes Numbers. 
     
     
         8 . The process according to  claim 1  wherein the plurality of first particles comprises absorbent material particles. 
     
     
         9 . The process according to  claim 8  wherein the absorbent material particles comprise super absorbent polymer particles. 
     
     
         10 . The process according to  claim 1  wherein the plurality of first particles comprises at least one particle that exhibits a size that is at least two times greater than the size of at least one other particle within the plurality of first particles. 
     
     
         11 . The process according to  claim 1  wherein the first fluid stream comprises a plurality of filaments commingled with a plurality of fibers. 
     
     
         12 . The process according to  claim 1  wherein the second fluid stream comprises an air stream comprising the plurality of first particles. 
     
     
         13 . The process according to  claim 1  wherein the non-random arrangement of the plurality of first particles in the composite fluid stream is such that the plurality of first particles are present in a machine direction gradient in the composite fluid stream based on a particle characteristic selected from the group consisting of: size, shape, mass, density, Stokes Number, and mixtures thereof. 
     
     
         14 . The process according to  claim 1  wherein the process further comprises the step of collecting the composite fluid stream on a collection device such that a fibrous structure exhibiting a non-random arrangement of the plurality of first particles in the fibrous structure is formed. 
     
     
         15 . The process according to  claim 1  wherein the non-random arrangement of the plurality of first particles in the fibrous structure is such that the plurality of first particles are present in a z-direction gradient in the fibrous structure based on a particle characteristic selected from the group consisting of: size, shape, mass, density, Stokes Number, and mixtures thereof. 
     
     
         16 . The process according to  claim 15  wherein the fibrous structure comprises a homogeneous z-direction concentration of the first particles. 
     
     
         17 . The process according to  claim 15  wherein the fibrous structure comprises a non-homogeneous z-direction concentration of the first particles. 
     
     
         18 . The process according to  claim 15  wherein the fibrous structure comprises two or more different z-direction layers of concentration of the first particles. 
     
     
         19 . The process according to  claim 1  wherein the process further comprises the step of depositing a scrim layer on at least one surface of the fibrous structure. 
     
     
         20 . A fibrous structure made according to the process according to  claim 1 .