Disposable absorbent product with coated element and related methods

Abstract

A disposable absorbent product includes a topsheet defining an interior face of the disposable absorbent product configured to face a wearer thereof during use. A backsheet overlays the topsheet, with the backsheet defining an exterior face of the disposable absorbent product configured to face away from the wearer during use. An absorbent core is disposed between the topsheet and the backsheet for storing fluid secreted by the wearer of the disposable absorbent product. The absorbent core includes at least one absorbent structure and a wrapping element that envelops the at least one absorbent structure. The wrapping element has a main substrate layer and an adhesive coating layer thereon that is substantially adhered to the substrate layer and which defines an impermeable film layer on the substrate.

What is claimed is: 
     
         1 . A disposable absorbent product comprising:
 a topsheet defining an interior face of the disposable absorbent product configured to face a wearer thereof during use;   a backsheet overlaying said topsheet, said backsheet defining an exterior face of the disposable absorbent product configured to face away from the wearer during use; and   an absorbent core disposed between said topsheet and said backsheet for storing fluid secreted by the wearer of the disposable absorbent product, said absorbent core including at least one absorbent structure and a wrapping element enveloping said at least one absorbent structure, said wrapping element having a main substrate layer and an adhesive coating layer thereon substantially adhered to said main substrate layer, substantially adhered to said at least one absorbent structure, and defining an impermeable film layer on said main substrate layer.   
     
     
         2 . The disposable absorbent product of  claim 1 , wherein said main substrate layer completely envelops said at least one absorbent structure, thereby defining a wrapping element with four walls surrounding said at least one absorbent structure, said four walls including two side walls, a top wall adjacent said topsheet, and a bottom wall adjacent said backsheet. 
     
     
         3 . The disposable absorbent product of  claim 1 , wherein said disposable absorbent product is free of any impermeable film layers disposed between said bottom wall and said backsheet. 
     
     
         4 . The disposable absorbent product of  claim 2 , wherein said top wall is substantially free of said adhesive coating layer. 
     
     
         5 . The disposable absorbent product of  claim 1 , wherein said main substrate layer only partially envelops said at least one absorbent structure, thereby defining a wrapping element with three walls surrounding said at least one absorbent structure, said three walls including two side walls, and a bottom wall adjacent said backsheet, said wrapping element being substantially free of a wall opposite said bottom wall, adjacent said topsheet. 
     
     
         6 . The disposable absorbent product of  claim 5 , wherein said main substrate layer and said adhesive coating layer have respective pairs of lateral ends, said lateral ends of said main substrate layer generally coinciding with said lateral ends of said adhesive coating layer. 
     
     
         7 . The disposable absorbent product of  claim 1 , wherein said at least one absorbent structure comprises first and second absorbent structures, said first absorbent structure being primarily configured for acquisition and distribution of fluid secreted by the wearer and said second absorbent structure being primarily configured for storage of fluid secreted by the wearer. 
     
     
         8 . The disposable absorbent product of  claim 7 , wherein said first absorbent structure is substantially free of granular components. 
     
     
         9 . The disposable absorbent product of  claim 1 , wherein said adhesive coating layer is formed from a hot-melt adhesive. 
     
     
         10 . The disposable absorbent product of  claim 1 , wherein said adhesive coating layer is tacky at room temperature. 
     
     
         11 . The disposable absorbent product of  claim 1 , wherein said adhesive coating layer has a basis weight of less than about 20 g/m2. 
     
     
         12 . The disposable absorbent product of  claim 11 , wherein said adhesive coating layer has a basis weight no greater than about 10 g/m2. 
     
     
         13 . The disposable absorbent product of  claim 12 , wherein said adhesive coating layer has a basis weight of at least about 5 g/m2 but less than about 10 g/m2. 
     
     
         14 . The disposable absorbent product of  claim 1 , wherein said backsheet is made of a nonwoven material. 
     
     
         15 . A disposable absorbent product comprising:
 a hydrophilic topsheet defining an interior face of the disposable absorbent product configured to face a wearer thereof during use;   a nonwoven backsheet overlaying said topsheet, said backsheet defining an exterior face of the disposable absorbent product configured to face away from the wearer during use; and   an absorbent core disposed between said topsheet and said backsheet for storing fluid secreted by the wearer of the disposable absorbent product, wherein:   said absorbent core includes at least one absorbent structure and a wrapping element enveloping said at least one absorbent structure, said wrapping element having a main substrate layer and an adhesive coating layer thereon, said adhesive coating layer defining an impermeable film layer on said main substrate layer, said adhesive coating layer is substantially adhered to said at least one absorbent structure,   said adhesive coating layer is formed from a hot-melt adhesive, is tacky at room temperature, and has a basis weight of less than about 20 g/m2, and   the disposable absorbent product is free of any impermeable barriers disposed between said bottom wall and said exterior face of the disposable absorbent product.   
     
     
         16 . A method for forming an absorbent core for use in a disposable absorbent product, wherein the absorbent core is disposed between a backsheet and a topsheet overlaying one another, the method comprising:
 obtaining an absorbent structure primarily configured for storage of fluid secreted by a wearer of the disposable absorbent product;   obtaining a main substrate layer;   applying a coat of adhesive material onto the main substrate layer to thereby define an impermeable film layer on the main substrate layer; and   enveloping the absorbent structure with the adhesive-coated main substrate layer so as to substantially adhere the coat of adhesive material to the absorbent structure, and to thereby define the absorbent core.   
     
     
         17 . The method of  claim 16 , further comprising:
 dispensing the adhesive material from a non-contact slot coating device and onto the main substrate layer.   
     
     
         18 . The disposable absorbent product of  claim 1 , wherein said wrapping element has two side walls and a bottom wall extending there between, said impermeable film layer extending continuously along one of said side walls, along said bottom wall, and along the other of said side walls. 
     
     
         19 . The disposable absorbent product of  claim 1 , wherein said adhesive coating layer includes a plasticizer. 
     
     
         20 . The disposable absorbent product of  claim 1 , wherein said main substrate layer directly contacts said at least one absorbent structure.