Absorbent article with absorbent core structure perimeter seal arrangements

Abstract

A disposable absorbent article having a topsheet, a backsheet, and an absorbent core structure therebetween. The absorbent core structure having an upper nonwoven layer, a lower nonwoven layer, and a portion of an inner core layer disposed therebetween. The portion of the inner core layer is contained within the upper and lower nonwoven layers by sealing a portion of the first and second side regions of the upper nonwoven layer with a portion of the first and second side regions of the lower nonwoven layer at a lateral perimeter seal. An adhesive is positioned between the upper and nonwoven layers in the perimeter seal. The lateral perimeter seal is positioned in the middle region and has a longitudinal seal length that is from about 45% to about 90% of the longitudinal inner core length.

What is claimed is: 
     
         1 . A disposable absorbent article comprising:
 a front end region, a middle region, and a back end region;   a topsheet;   a backsheet; and   an absorbent core structure disposed between the topsheet and backsheet, wherein the absorbent core structure comprises:   a. an upper nonwoven layer comprising polymer fibers and having a basis weight of from about 30 gsm to about 65 gsm; wherein the upper nonwoven layer comprises a first side region, a laterally opposing second side region, and a first nonwoven lateral width;   b. a lower nonwoven layer comprising polymer fibers and having a basis weight of from about 10 gsm to about 40 gsm; wherein the lower nonwoven layer comprises a first side region, a laterally opposing second side region, and a nonwoven second lateral width; and   c. an inner core layer having a longitudinal inner core length, a first inner core layer lateral width, and a second inner core lateral width; wherein a portion of the inner core layer is disposed between the upper nonwoven layer and the lower nonwoven layer;   wherein the inner core layer comprises a liquid absorbent material comprising from about 50% to about 85% cellulosic fibers, by weight of the inner core layer, and from about 15% to about 50% superabsorbent particles, by weight of the inner core layer; wherein the absorbent core structure has an average density of between about 0.045 g/cm3 and about g/cm3;   wherein the portion of the inner core layer is contained within the upper nonwoven layer and the lower nonwoven layer by sealing a portion of the first side region and the second side region of the upper nonwoven layer with a portion of the first side region and the second side region of the lower nonwoven layer at a lateral perimeter seal, wherein an adhesive is positioned between the upper nonwoven layer and the lower nonwoven layer in the perimeter seal;   wherein the lateral perimeter seal is positioned in the middle region and has a longitudinal seal length that is from about 45% to about 90% of the longitudinal inner core length.   
     
     
         2 . The disposable absorbent article of  claim 1 , wherein the first inner core layer lateral width is greater than at least one of the first nonwoven lateral width and the second nonwoven lateral width. 
     
     
         3 . The disposable absorbent article of  claim 1 , wherein the second inner core layer lateral width is greater than at least one of the first nonwoven lateral width and the second nonwoven lateral width. 
     
     
         4 . The disposable absorbent article of  claim 1 , wherein the entire inner core layer is disposed between the upper nonwoven layer and the lower nonwoven layer. 
     
     
         5 . The disposable absorbent article of  claim 1 , wherein the upper nonwoven layer and the lower nonwoven layer are further joined by at least one of a front perimeter seal region and a back perimeter seal region. 
     
     
         6 . The disposable absorbent article of  claim 5 , wherein the at least one front perimeter seal region and the back perimeter seal region extend longitudinally outboard from an inner core layer perimeter a distance of from about 3 mm to about 30 mm. 
     
     
         7 . The disposable absorbent article of  claim 1 , wherein the first nonwoven lateral width and the second nonwoven lateral width are different. 
     
     
         8 . The disposable absorbent article of  claim 1 , wherein the first nonwoven lateral width and the second nonwoven lateral width are the same. 
     
     
         9 . The disposable absorbent article of  claim 1 , wherein the absorbent article comprises a front article edge and a back article edge; wherein the upper nonwoven layer and the lower nonwoven layer each comprise a front edge; wherein the front edge of at least one of the upper nonwoven layer and the lower nonwoven layer is coterminous with the front article edge. 
     
     
         10 . The disposable absorbent article of  claim 9 , wherein the upper nonwoven layer and the lower nonwoven layer each comprise a back edge and the back edge of at least one of the upper nonwoven layer and the lower nonwoven layer is coterminous with the back article edge. 
     
     
         11 . The disposable absorbent article of  claim 1 , wherein at least one of the upper nonwoven layer and the lower nonwoven layer is shaped. 
     
     
         12 . The disposable absorbent article of  claim 1 , further comprising a crimp seal comprising the topsheet, the backsheet, and at least one of the upper nonwoven layer and the lower nonwoven layer. 
     
     
         13 . The disposable absorbent article of  claim 12 , wherein the crimp seal is positioned in at least one of the front end region and the back end region. 
     
     
         14 . The disposable absorbent article of  claim 12 , wherein the crimp seal is substantially free of the liquid absorbent material. 
     
     
         15 . The disposable absorbent article of  claim 1 , wherein the lateral perimeter seal has a maximum seal width of from about 1 mm to about 15 mm. 
     
     
         16 . A disposable absorbent article comprising:
 a front end region, a middle region, and a back end region;   a topsheet;   a backsheet; and   an absorbent core structure disposed between the topsheet and backsheet, wherein the absorbent core structure comprises:   a. an upper nonwoven layer comprising polymer fibers and having a basis weight of from about 30 gsm to about 65 gsm; wherein the upper nonwoven layer comprises a first side region and a laterally opposing second side region;   b. a lower nonwoven layer comprising polymer fibers and having a basis weight of from about 10 gsm to about 40 gsm; wherein the lower nonwoven layer comprises a first side region and a laterally opposing second side region;   c. an inner core layer comprising a first side edge and a laterally opposing second side edge and having a longitudinal inner core length; wherein the inner core layer is positioned between the upper nonwoven layer and the lower nonwoven layer; and   d. an adhesive zone disposed intermediate a portion of at least one of the upper nonwoven layer and the lower nonwoven layer and the inner core layer;   wherein the inner core layer comprises a liquid absorbent material comprising a cellulosic fiber and a superabsorbent particle, and wherein the absorbent core structure has an average density of between about 0.045 g/cm3 and about 0.15 g/cm3;   wherein the upper nonwoven layer and the lower nonwoven layer substantially surrounds the adhesive zone and the inner core layer;   wherein a portion of the adhesive zone extends laterally outboard of the first and second side edges of the inner core layer and bonds the upper nonwoven layer to the lower nonwoven layer at a lateral perimeter seal;   wherein a portion of the inner core layer extends laterally outboard of the adhesive zone to define an unsealed portion; wherein the unsealed portion is positioned longitudinally outboard of the lateral perimeter seal.   
     
     
         17 . The disposable absorbent article of  claim 16 , wherein the lateral perimeter seal is positioned in the middle region. 
     
     
         18 . The disposable absorbent article of  claim 16 , wherein the unsealed portion has an unsealed longitudinal length that is about 5% to about 30% of the longitudinal inner core length. 
     
     
         19 . The disposable absorbent article of  claim 16 , wherein the unsealed portion is positioned in the back end region. 
     
     
         20 . The disposable absorbent article of  claim 16 , wherein a second portion of the shaped inner core layer extends laterally outboard of the adhesive zone to define a second unsealed region; wherein the second unsealed region is positioned longitudinally outboard of the perimeter seal. 
     
     
         21 . The disposable absorbent article of  claim 16 , wherein the inner core layer has a first inner core layer lateral width, a second inner core layer lateral width, and a third inner core layer lateral width disposed therebetween. 
     
     
         22 . The disposable absorbent article of  claim 21 , wherein the third inner core layer lateral width is less than the first inner core layer lateral width and the second inner core layer lateral width. 
     
     
         23 . The disposable absorbent article of  claim 22 , wherein the second inner core layer lateral width is greater than the first inner core layer lateral width and the third inner core layer lateral width. 
     
     
         23 . The disposable absorbent article of  claim 21 , wherein the adhesive zone has an adhesive zone lateral width, and wherein the first inner core layer lateral width and the adhesive zone lateral width are substantially the same. 
     
     
         24 . The disposable absorbent article of  claim 21 , wherein the adhesive zone has an adhesive zone lateral width, and wherein the adhesive zone lateral width is greater than the first inner core layer lateral width.