Bonded fluff structures and process for producing same

Abstract

Bonded fluff structures and a method for producing such bonded fluff structures in which a pulp sheet having a material suitable for producing fluff and a heat activatable fiber material is fiberized to produce a mixture of fluff and heat activatable fibers. The mixture is contacted with a hot air stream, heating the heat activatable fibers to an activation temperature. The resulting heated mixture is then deposited onto a forming structure, forming a bonded fluff/fiber composite matrix structure.

We claim:  
     
         1 . A personal care absorbent article, comprising: 
 a liquid pervious inner layer;    a bonded fluff structure adjacent the inner layer, the bonded fluff structure comprising a fluff material and a heat activated fiber; and    a liquid impervious outer layer adjacent the bonded fluff structure;    wherein the bonded fluff structure has a basis weight of about 200 grams/meter 2  or less and a tensile strength of at least about 100 grams.    
     
     
         2 . The absorbent article of  claim 1 , wherein the bonded fluff structure has a tensile strength of at least about 125 grams.  
     
     
         3 . The absorbent article of  claim 2 , wherein the bonded fluff structure has a tensile strength of at least about 150 grams.  
     
     
         4 . The absorbent article of  claim 1 , wherein the heat activated fiber comprises a bicomponent binder fiber.  
     
     
         5 . The absorbent article of  claim 4 , wherein the bicomponent binder fiber comprises polypropylene and polyethylene polymers.  
     
     
         6 . The absorbent article of  claim 1 , wherein the bonded fluff structure further comprises a density gradient.  
     
     
         7 . The absorbent article of  claim 1 , wherein the bonded fluff structure has a three-dimensional shape.  
     
     
         8 . The absorbent article of  claim 1 , wherein the bonded fluff structure further comprises at least one superabsorbent material.  
     
     
         9 . The absorbent article of  claim 1 , wherein the bonded fluff structure is produced by hot air fiberizing a fluff/heat activatable fiber pulp sheet resulting in formation of a fluff/fiber mixture and depositing said fluff/fiber mixture onto a forming structure resulting in formation of a fluff/fiber composite matrix.  
     
     
         10 . The absorbent article of  claim 1  comprising a diaper.  
     
     
         11 . The absorbent article of  claim 1  comprising a feminine care article.  
     
     
         12 . A bonded fluff structure produced by hot air fiberizing a fluff/heat activatable fiber pulp sheet resulting in formation of a fluff/fiber mixture and depositing said flufffiber mixture onto a forming structure resulting in formation of a fluff/fiber composite matrix, wherein the bonded fluff structure has a basis weight of about 200 grams/meter 2  or less and a tensile strength of at least about 100 grams.  
     
     
         13 . A bonded fluff structure in accordance with  claim 12 , wherein the bonded fluff structure has a tensile strength of at least about 125 grams.  
     
     
         14 . A bonded fluff structure in accordance with  claim 13 , wherein the bonded fluff structure has a tensile strength of at least about 150 grams.  
     
     
         15 . A bonded fluff structure in accordance with  claim 12 , wherein the heat activatable fiber comprises a bicomponent binder fiber.  
     
     
         16 . A bonded fluff structure in accordance with  claim 17 , wherein the bicomponent binder fiber comprises polypropylene and polyethylene polymers.  
     
     
         17 . A bonded fluff structure in accordance with  claim 12 , further comprising a density gradient.  
     
     
         18 . A bonded fluff structure in accordance with  claim 12 , further comprising a three-dimensional shape.  
     
     
         19 . A bonded fluff structure in accordance with  claim 12 , further comprising at least one superabsorbent material.  
     
     
         20 . A bonded fluff structure in accordance with  claim 12 , further comprising at least one odor control material.  
     
     
         21 . A disposable diaper comprising: 
 a bonded fluff structure produced by hot air fiberizing a fluff/heat activatable fiber pulp sheet resulting in formation of a fluff/fiber mixture and depositing said fluff/fiber mixture onto a forming structure resulting in formation of a fluff/fiber composite matrix, wherein the bonded fluff structure has a basis weight of about 200 grams/meter 2  or less and a tensile strength of at least about 100 grams.    
     
     
         22 . A feminine care article comprising: 
 a bonded fluff structure produced by hot air fiberizing a fluff/heat activatable fiber pulp sheet resulting in formation of a fluff/fiber mixture and depositing said fluff/fiber mixture onto a forming structure resulting in formation of a fluff/fiber composite matrix, wherein the bonded fluff structure has a basis weight of about 200 grams/meter 2  or less and a tensile strength of at least about 100 grams.    
     
     
         23 . A bonded fluff structure produced by hot air fiberizing a fluff/heat activatable fiber pulp sheet resulting in formation of a fluff/fiber mixture and depositing said fluff/fiber mixture onto a forming structure resulting in formation of a fluff/fiber composite matrix comprising bonded heat activated fibers.