Absorbent articles and methods of making

Abstract

An absorbent article comprising an absorbent core sandwiched between a liquid permeable topsheet and a liquid impermeable backsheet, and an acquisition distribution system positioned between said topsheet and said absorbent core, wherein the absorbent core comprises absorbent material selected from the group consisting of cellulose fibers, superabsorbent polymers and combinations thereof, wherein said absorbent material is contained within at least one core wrap substrate enclosing said absorbent material, and wherein a top layer of said core wrap is adhered to a bottom layer of said core wrap to form one or more channels substantially free of said absorbent material, wherein said channels have a length extending along a longitudinal axis and the absorbent core has a length extending along said longitudinal axis and wherein the length of said channels is from 10% to 95% of the length of said absorbent core and wherein said channels each follow a substantially continuous path such as from a first end of a channel to a second end of the same channel wherein the acquisition distribution system is multi-layered and comprises at least one spunbond layer and at least one meltblown layer, and wherein said acquisition distribution system is positioned between said absorbent core and said topsheet such that said spunbond and/or meltblown layers are in direct contact with said absorbent core and said topsheet.

1 . An absorbent article ( 10 ,  20 ,  300 ,  500 ,  600 ) comprising an absorbent core ( 101 ,  501 ,  601 ) sandwiched between a liquid permeable topsheet ( 520 ,  620 ) and a liquid impermeable backsheet ( 521 ,  621 ), and an acquisition distribution system ( 201 ,  522 ,  622 ) positioned between said topsheet ( 520 ,  620 ) and said absorbent core ( 101 ,  501 ,  601 ), wherein the absorbent core ( 101 ,  501 ,  601 ) comprises absorbent material selected from the group consisting of cellulose fibers, superabsorbent polymers and combinations thereof, wherein said absorbent material is contained within at least one core wrap substrate enclosing said absorbent material, and wherein a top layer of said core wrap is adhered to a bottom layer of said core wrap to form one or more channels ( 106 ) substantially free of said absorbent material, wherein said channels ( 106 ) have a length extending along a longitudinal axis ( 48 ) and the absorbent core ( 101 ,  501 ,  601 ) has a length extending along said longitudinal axis ( 48 ) and wherein the length of said channels ( 106 ) is from 10% to 95% of the length of said absorbent core ( 101 ,  501 ,  601 ) and wherein said channels each follow a substantially continuous path
 characterized in that the acquisition distribution system ( 201 ,  522 ,  622 ) comprises at least one spunbond layer and/or at least one carded nonwoven layer, and   wherein said acquisition distribution system ( 201 ,  522 ,  622 ) is the top layer of the core wrap and is positioned between said absorbent core ( 101 ,  501 ,  601 ) and said topsheet ( 520 ,  620 ) such that at least a substantial portion of said spunbond and/or carded nonwoven layer is in direct contact with said absorbent core ( 101 ,  501 ,  601 ) and said topsheet ( 520 ,  620 ), and wherein the acquisition distribution system ( 201 ,  522 ,  622 ) comprises synthetic fibers, wherein said synthetic fibers are comprised at a level of greater than 80% wt by weight of said acquisition distribution layer ( 201 ,  522 ,  622 ), and wherein said acquisition distribution layer ( 201 ,  522 ,  622 ) has a basis weight of from 5 to 50 g/m 2 .   
     
     
         2 . An absorbent article according to  claim 1  wherein the acquisition distribution system ( 201 ,  522 ,  622 ) is a nonwoven selected from the group consisting of: SM, SMS, SMMS, and combinations thereof. 
     
     
         3 .- 6 . (canceled) 
     
     
         7 . An absorbent article according to  claim 1 , wherein the at least one of the channels ( 106 ) extends both along the longitudinal axis ( 48 ) and along an axis perpendicular to said longitudinal axis ( 48 ), such that a shape is formed that is substantially U-shaped. 
     
     
         8 . An absorbent article according to  claim 1 , wherein the acquisition distribution system ( 201 ,  522 ,  622 ) has a specific volume of less than 11.4 cm 3 /g. 
     
     
         9 . An absorbent article according to  claim 1 , wherein the acquisition distribution system ( 201 ,  522 ,  622 ) has a mean flow pore size of from 15 μm to 200 μm. 
     
     
         10 . An absorbent article according to  claim 1 , wherein the acquisition distribution system ( 201 ,  522 ,  622 ) has a relative porosity of less than 9000 L/m 2 /s. 
     
     
         11 . An absorbent article according to  claim 1  wherein the second end ( 110 ′, 111 ′) of at least one channel is at a distance from the first end ( 110 ,  111 ) of at least one other channel taken along the longitudinal axis ( 48 ), such that at least two spaced apart channels are formed along said longitudinal axis ( 48 ) that are offset from a transverse line running perpendicular from said longitudinal axis ( 48 ) and wherein said distance taken along the longitudinal axis ( 48 ) is less than 18 mm. 
     
     
         12 . An absorbent article according to  claim 1  wherein the top layer of said core wrap is adhered to a bottom layer of said core wrap, along said channels ( 106 ), at a plurality of discrete joining areas, wherein said joining areas form a pattern consisting of elongated oblique members ( 1061 ) having an angle α from the longitudinal axis ( 48 ), wherein said angle α is greater than 0° and less than 90°. 
     
     
         13 . An absorbent article according to  claim 1  wherein the acquisition distribution system ( 201 ,  522 ,  622 ) is adhered to the absorbent core ( 101 ,  501 ,  601 ) at one or more joining zones that are positioned outboard and/or inboard of said channel(s) ( 106 ) such that said joining zones do not substantially overlap the channel(s) ( 106 ). 
     
     
         14 . An absorbent article according to  claim 1  wherein the acquisition distribution system ( 201 ,  522 ,  622 ) has a thickness of less than 0.5 mm. 
     
     
         15 .- 17 . (canceled) 
     
     
         18 . An absorbent article according to  claim 1  wherein the acquisition distribution layer ( 201 ,  522 ,  622 ) has a basis weight of from 15 to 40 g/m 2 . 
     
     
         19 . An absorbent article according to  claim 1  wherein the acquisition distribution layer ( 201 ,  522 ,  622 ) has a basis weight of from 18 to 35 g/m 2 . 
     
     
         20 . An absorbent article according to  claim 1  wherein the acquisition distribution layer ( 201 ,  522 ,  622 ) has a basis weight of from 20 to 30 g/m 2 . 
     
     
         21 . An absorbent article according to  claim 1  wherein the acquisition distribution system ( 201 ,  522 ,  622 ) is multi-layered and comprises at least one meltblown layer. 
     
     
         22 . An absorbent article according to  claim 1  wherein the acquisition distribution system ( 201 ,  522 ,  622 ) comprises at least one spunbond layer. 
     
     
         23 . An absorbent article according to  claim 1  wherein the acquisition distribution system ( 201 ,  522 ,  622 ) comprises at least one carded nonwoven layer. 
     
     
         24 . An absorbent article according to  claim 11  wherein the core comprises at least four channels ( 106 ) and wherein said distance between second and first ends ( 110 , 111 , 110 ′, 111 ′) of a first pair of longitudinally displaced channels is different from the distance between second and first ends ( 110 , 111 , 110 ′, 111 ′) of a second pair of longitudinally displaced channels wherein the first pair of channels run substantially parallel to the second pair of channels. 
     
     
         25 . An absorbent article according to  claim 12  wherein at least one of said elongated oblique members ( 1061 ) have a total length (Lo) which is at least substantially equal to the width (wc) of the channel along an axis perpendicular to the longitudinal axis ( 48 ). 
     
     
         26 . An absorbent article according to  claim 25  wherein said discrete joining areas are free of adhesive. 
     
     
         27 . An absorbent article according to  claim 1  wherein the acquisition distribution layer ( 201 ,  522 ,  622 ) has a wetness retention factor of less than 11 as measured according to the Wetness retention factor test method herein.