Fluted composite and related absorbent articles

Abstract

An absorbent composite that includes a fibrous matrix having absorbent material dispersed in bands along the composite's length is disclosed. The bands define liquid distribution zones. On liquid contact, absorbent material swelling occurs and produces a wetted composite having flutes that include swollen absorbent material separated by distribution zones, regions of the composite that are substantially free of absorbent material. Absorbent articles that include the composite are also disclosed.

1 . An absorbent composite comprising a fibrous matrix and superabsorbent material, wherein the superabsorbent material is distributed directly in the fibrous matrix in two or more bands, wherein each band is continuous along the composite's length, wherein the regions between the bands comprise fibrous liquid distribution zones, and wherein the fibrous matrix comprises crosslinked cellulosic fibers.  
     
     
         2 . The composite of  claim 1  wherein the distribution zones are substantially free of superabsorbent material.  
     
     
         3 . The composite of  claim 1  wherein the bands are substantially parallel.  
     
     
         4 . The composite of  claim 1  wherein the bands further comprise fibrous material.  
     
     
         5 . The composite of  claim 4  wherein the fibrous material comprises fibers selected from the group consisting of resilient fibers, matrix fibers, and mixtures thereof.  
     
     
         6 . The composite of  claim 1  wherein the fibrous matrix comprises fibers selected from the group consisting of resilient fibers, matrix fibers, and mixtures thereof.  
     
     
         7 . The composite of  claim 6  wherein the resilient fibers are selected from the group consisting of chemically stiffened fibers, anfractuous fibers, chemithermomechanical pulp fibers, prehydrolyzed kraft pulp fibers, synthetic fibers, and mixtures thereof.  
     
     
         8 . The composite of  claim 7  wherein the chemically stiffened fibers comprise crosslinked cellulosic fibers.  
     
     
         9 . The composite of  claim 8  wherein the crosslinked cellulosic fibers are crosslinked with a crosslinking agent selected from the group consisting of urea-based and polycarboxylic acid crosslinking agents.  
     
     
         10 . The composite of  claim 7  wherein the synthetic fibers are selected from the group consisting of polyolefin, polyester, polyamide, and thermobondable bicomponent fibers.  
     
     
         11 . The composite of  claim 10  wherein the polyester fibers are polyethylene terephthalate fibers.  
     
     
         12 . The composite of  claim 6  wherein the matrix fibers comprise cellulosic fibers.  
     
     
         13 . The composite of  claim 12  wherein the cellulosic fibers comprise fibers selected from the group consisting of wood pulp fibers, cotton linters, cotton fibers, hemp fibers, and mixtures thereof.  
     
     
         14 . The composite of  claim 6  wherein the resilient fibers are present in the composite in an amount from about 10 to about 60 percent by weight of the total composite.  
     
     
         15 . The composite of  claim 6  wherein the matrix fibers are present in the composite in an amount from about 10 to about 50 percent by weight of the total composite.  
     
     
         16 . The composite of  claim 1  wherein the superabsorbent material is selected from the group consisting of superabsorbent particles and superabsorbent fibers.  
     
     
         17 . The composite of  claim 1  wherein the superabsorbent material is present in an amount from about 0.1 to about 80 percent by weight of the total composite.  
     
     
         18 . The composite of  claim 1  wherein the superabsorbent material is present in about 40 percent by weight of the total composite.  
     
     
         19 . The composite of  claim 1  wherein the superabsorbent material absorbs from about 5 to about 100 times its weight in 0.9 percent saline solution.  
     
     
         20 . The composite of  claim 1  further comprising a wet strength agent.  
     
     
         21 . The composite of  claim 20  wherein the wet strength agent is a resin selected from the group consisting of polyamide-epichlorohydrin and polyacrylamide resins.  
     
     
         22 . The composite of  claim 20  wherein the wet strength agent is present in the composite in an amount from about 0.01 to about 2 percent by weight of the total composite.  
     
     
         23 . The composite of  claim 20  wherein the wet strength agent is present in the composite in about 0.25 percent by weight of the total composite.  
     
     
         24 . The composite of  claim 1  having a basis weight of from about 50 to about 1000 g/m 2 .  
     
     
         25 . The composite of  claim 1  having a density of from about 0.02 to about 0.7 g/cm 3 .  
     
     
         26 . The composite of  claim 1  wherein the fibrous matrix comprises crosslinked cellulosic fibers present in about 45 percent by weight based on the total weight of the composite.  
     
     
         27 . The composite of  claim 1  wherein the fibrous matrix comprises wood pulp fibers present in about 15 percent by weight based on the total weight of the composite.  
     
     
         28 . The composite of  claim 1  wherein the fibrous matrix further comprises superabsorbent material.  
     
     
         29 . A wetlaid absorbent composite comprising a fibrous matrix and superabsorbent material, wherein the superabsorbent material is distributed directly in the fibrous matrix in two or more bands, wherein each band is continuous along the composite's length, wherein the regions between the bands comprise fibrous liquid distribution zones, and wherein the fibrous matrix comprises crosslinked cellulosic fibers.  
     
     
         30 . An absorbent composite, comprising a fibrous matrix and superabsorbent material, wherein the superabsorbent material is distributed directly in the fibrous matrix in two or more bands, wherein each band is continuous along the composite's length, wherein the bands swell and form a fluted structure upon contact with liquid, wherein the regions between the bands comprise fibrous liquid distribution zones, and wherein the fibrous matrix comprises crosslinked cellulosic fibers.  
     
     
         31 . The composite of  claim 30  wherein the composite has a width and a length and wherein the bands and liquid distribution zones alternate across the composite's width and extend along the composite's length.