Absorbent article having a multilayer blended core and a method of forming

Abstract

An absorbent article, such as a thin incontinence pad or pantyliner, is disclosed which has an absorbent core formed from multiple layers of blended material for providing protection against involuntary urine loss. A method of forming the absorbent article is also disclosed. The absorbent article includes a liquid permeable bodyside liner, a liquid-impermeable baffle, and first and second absorbents positioned between the liner and the baffle. The first absorbent is a stabilized material containing a superabsorbent and has a predetermined basis weight. The second absorbent is also a stabilized material containing a superabsorbent. The second absorbent is positioned below the first absorbent and has a basis weight that is at least equal to the basis weight of the first absorbent.

We claim:  
     
         1 . An absorbent core for an absorbent article, said absorbent core comprising a blend of fibers including a first group of short, high denier hydrophilic fibers, and a second group of longer, lower denier, moisture insensitive crimped synthetic fibers, said second group of fibers making up at least about 5% of said absorbent core, by weight, and said absorbent core being compressed in a substantially dry condition to a density of at least about 0.09 g/cm 3 .  
     
     
         2 . An absorbent core for an absorbent article, said absorbent core comprising first and second absorbent layers each comprising a blend of fibers including a first group of short, high denier hydrophilic fibers, and a second group of longer, lower denier, moisture insensitive crimped synthetic fibers, said second group of fibers making up at least about 5% of each of said first and second absorbent layers, by weight, and each of said first and second absorbent layers being compressed in a substantially dry condition to a density of at least about 0.09 g/cm 3 .  
     
     
         3 . An absorbent article, comprising: 
 a) a liquid permeable liner;    b) a liquid-impermeable baffle;    c) a first absorbent positioned between said liner and said baffle, said first absorbent being a stabilized material containing a superabsorbent, and having a predetermined basis weight; and    d) a second absorbent positioned between said first absorbent and said baffle, said second absorbent being a stabilized material containing a superabsorbent, and having a basis weight which is at least equal to said basis weight of said first absorbent.    
     
     
         4 . The absorbent article of  claim 3  wherein said first absorbent is an airlaid constructed of cellulosic fibers, a binder and a superabsorbent, and has a basis weight of from between about 100 gsm to about 600 gsm.  
     
     
         5 . The absorbent article of  claim 4  wherein said binder comprises binder fibers having a length of from between about 3 millimeters to about 6 millimeters.  
     
     
         6 . The absorbent article of  claim 3  wherein said second absorbent is an airlaid constructed of cellulosic fibers, a binder and a superabsorbent, and has a basis weight of from between about 100 gsm to about 600 gsm.  
     
     
         7 . The absorbent article of  claim 6  wherein said binder comprises binder fibers having a length of from between about 3 millimeters to about 6 millimeters.  
     
     
         8 . The absorbent article of  claim 3  wherein said second absorbent is folded.  
     
     
         9 . The absorbent article of  claim 3  wherein said second absorbent comprises two separate layers.  
     
     
         10 . The absorbent article of  claim 3  wherein said first and second absorbents are of similar compositions.  
     
     
         11 . The absorbent article of  claim 3  wherein said first and second absorbents have a combined thickness of less than about 4 millimeters.  
     
     
         12 . An absorbent article, comprising: 
 a) a liquid permeable liner;    b) a liquid-impermeable baffle;    c) a first absorbent positioned between said liner and said baffle, said first absorbent being a stabilized material containing a superabsorbent, and having a predetermined basis weight; and    d) a second absorbent positioned between said first absorbent and said baffle, said second absorbent being a stabilized material containing a superabsorbent, and having a basis weight which is at least equal to said basis weight of said first absorbent, and said second absorbent having a smaller surface area than said first absorbent.    
     
     
         13 . The absorbent article of  claim 12  wherein said first absorbent has a shaped configuration.  
     
     
         14 . The absorbent article of  claim 13  wherein said first absorbent has an asymmetrical configuration.  
     
     
         15 . The absorbent article of  claim 13  wherein said first absorbent has a dog bone shape.  
     
     
         16 . The absorbent article of  claim 12  having a fluid retention capacity of from between about 20 grams to about 100 grams.  
     
     
         17 . The absorbent article of  claim 12  having a fluid retention capacity of about 50 grams.  
     
     
         18 . An absorbent article comprising: 
 a) a liquid permeable liner;    b) a liquid-impermeable baffle;    c) a first absorbent positioned between said liner and said baffle, said first absorbent being an airlaid material constructed of cellulosic fibers, a binder and superabsorbent particles, and having a basis weight of from between about 100 gsm to about 400 gsm; and    d) a second absorbent positioned between said first absorbent and said baffle, said second absorbent being an airlaid material constructed of cellulosic fibers, a binder and superabsorbent particles, and having a basis weight of from between about 200 gsm to about 600 gsm, said basis weight of said second absorbent being greater than said basis weight of said first absorbent, and said first and second absorbents are of similar composition.    
     
     
         19 . The absorbent article of  claim 18  wherein said superabsorbent particles contained in each of said first and second absorbents are similar in composition.  
     
     
         20 . The absorbent article of  claim 18  wherein said second absorbent has a basis weight which is at least 1.5 times greater than said basis weight of said first absorbent.  
     
     
         21 . The absorbent article of  claim 20  wherein said second absorbent has a basis weight which is about 2 times greater than said basis weight of said first absorbent.  
     
     
         22 . The absorbent article of  claim 18  wherein said absorbent article has a thickness of from between about 3 millimeters to about 5 millimeters.  
     
     
         23 . An absorbent article comprising: 
 a) a liquid permeable liner;    b) a liquid-impermeable baffle;    c) a transfer layer positioned adjacent to said liner which is capable of directing body fluid downward away from said liner;    d) a first absorbent positioned adjacent to said transfer layer, said first absorbent being an airlaid material constructed of cellulosic fibers, a binder and superabsorbent particles, and having a basis weight of from between about 100 gsm to about 400 gsm; and    e) a second absorbent positioned between said first absorbent and said baffle, said second absorbent being an airlaid material constructed of cellulosic fibers, a binder and superabsorbent, and having a basis weight of from between about 200 gsm to about 600 gsm, said basis weight of said second absorbent being greater than said basis weight of said first absorbent, and said first and second absorbents are of similar composition.    
     
     
         24 . The absorbent article of  claim 23  wherein said absorbent article has a thickness of less than about 5 millimeters.  
     
     
         25 . The absorbent article of  claim 23  wherein said first absorbent contains from between about 30% to about 85% cellulosic fibers, from between about 5% to about 20% binder fibers, and from between about 10% to about 60% superabsorbent.  
     
     
         26 . The absorbent article of  claim 23  wherein said second absorbent contains from between about 30% to about 85% cellulosic fibers, from between about 5% to about 20% binder fibers, and from between about 10% to about 60% superabsorbent.  
     
     
         27 . The absorbent article of  claim 23  wherein said binder comprises crimped binder fibers.  
     
     
         28 . The absorbent article of  claim 27  wherein said binder fibers are bicomponent fibers each having a polyester core surrounded by a polyethylene sheath.  
     
     
         29 . The absorbent article of  claim 27  wherein said binder fibers are bicomponent fibers each having a polypropylene core surrounded by a polyethylene sheath.  
     
     
         30 . The absorbent article of  claim 23  wherein said second absorbent has a basis weight which is a whole number multiple of the basis weight of said first absorbent.  
     
     
         31 . A method of forming an absorbent core comprising the steps of: 
 a) forming a first absorbent into a shaped configuration from an elongated strip of a stabilized material, said stabilized material containing a superabsorbent, said first absorbent having a predetermined basis weight;    b) forming a second absorbent of double its thickness from an elongated strip of stabilized material, said stabilized material containing a superabsorbent, said second absorbent having a basis weight which is greater than the basis weight of said first absorbent; and    c) positioning said second absorbent directly below and in contact with said first absorbent to form said absorbent core.    
     
     
         32 . The method of  claim 31  wherein said stabilized material used to form said first and second absorbents is the same composition.  
     
     
         33 . The method of  claim 31  wherein said stabilized material is airlaid.  
     
     
         34 . The method of  claim 31  wherein said first absorbent is formed with a die cutter.  
     
     
         35 . The method of  claim 31  wherein said second absorbent is doubled in thickness by C-folding said second absorbent.  
     
     
         36 . The method of  claim 31  wherein said second absorbent is doubled in thickness by U-folding said second absorbent.  
     
     
         37 . The method of  claim 31  wherein said second absorbent is doubled in thickness by slitting said second absorbent into two layers.