Disposable Absorbent Article with Varied Distribution of Absorbent Particulate Polymer Material and Method of Making Same

Abstract

A disposable absorbent article comprising an absorbent core located in a chassis and comprising absorbent particulate polymer material having a basis weight that varies across the absorbent core. Methods for making such an absorbent core and corresponding disposable absorbent article are also disclosed.

What is claimed is: 
     
         1 . An absorbent article comprising:
 a lateral axis;   a longitudinal axis;   a front waist region on a first side of the lateral axis;   a back waist region on a second side of the lateral axis;   a first longitudinal side edge on a first side of the longitudinal axis;   a second longitudinal side edge on a second side of the longitudinal axis:   a first elastic leg feature proximate to the first longitudinal side edge;   a second elastic leg feature proximate to the second longitudinal side edge;   a topsheet;   a backsheet;   an absorbent core positioned between the topsheet and the backsheet, wherein the absorbent core comprises:
 a first area of absorbent particulate polymer material positioned at least partially between the longitudinal axis and the first longitudinal side edge; 
 a second area of absorbent particulate polymer material positioned at least partially between the longitudinal axis and the second longitudinal side edge; and 
 a third area of absorbent particulate polymer material; 
   wherein the first area of absorbent particulate polymer material is convex relative to the longitudinal axis and concave relative to the first longitudinal side edge,   wherein the second area of absorbent particulate polymer material is convex relative to the longitudinal axis and concave relative to the second longitudinal side edge,   wherein the third area of absorbent particulate polymer material substantially surrounds the first area of absorbent particulate polymer material and the second area of absorbent particulate polymer material, and   wherein the first area of absorbent particulate polymer material has a first basis weight, wherein the second area of absorbent particulate polymer material has a second basis weight, wherein the third area of absorbent particulate polymer material has a third basis weight, and wherein the third basis weight is different than each of the first basis weight and the second basis weight.   
     
     
         2 . The absorbent article of  claim 1 , wherein the absorbent core is substantially cellulose free. 
     
     
         3 . The absorbent article of  claim 1 , wherein the disposable absorbent article is a diaper or a pant. 
     
     
         4 . The absorbent article of  claim 1 , wherein the third basis weight varies in a direction parallel to the longitudinal axis. 
     
     
         5 . The absorbent article of  claim 1 , wherein the third basis weight varies in a direction perpendicular to the longitudinal axis. 
     
     
         6 . The absorbent article of  claim 1 , wherein the absorbent core is hourglass or rectangular shaped. 
     
     
         7 . The absorbent article of  claim 1 , comprising an acquisition system disposed between the topsheet and the backsheet, wherein the acquisition system comprises one or more acquisition layers. 
     
     
         8 . The absorbent article of  claim 1 , comprising an acquisition system comprising a nonwoven hydrophilic acquisition layer and a layer of chemically cross-linked cellulosic fibers. 
     
     
         9 . The absorbent article of  claim 1 , wherein the absorbent core comprises:
 a first absorbent layer, wherein the first absorbent layer comprises:
 a first portion of absorbent particulate polymer material disposed on a first substrate; and 
 a first thermoplastic composition disposed on a portion of the first portion of absorbent particulate polymer material and a portion of the first substrate forming one or more land areas and one or more junction areas. 
   
     
     
         10 . The absorbent article of  claim 9 , wherein the absorbent core comprises:
 a second absorbent layer, wherein the first absorbent layer comprises:   a second portion of absorbent particulate polymer material disposed on a second substrate; and   a second thermoplastic composition disposed on a portion of the second portion of absorbent particulate polymer material and a portion of the second substrate forming one or more land areas and one or more junction areas.   
     
     
         11 . The absorbent article of  claim 10 , wherein the first absorbent layer is placed in facing relationship with the second absorbent layer. 
     
     
         12 . The absorbent article of  claim 1 , comprising an elastic waist feature disposed in the front waist region. 
     
     
         13 . An absorbent article comprising:
 a lateral axis;   a longitudinal axis;   a front waist region on a first side of the lateral axis;   a back waist region on a second side of the lateral axis;   a first longitudinal side edge on a first side of the longitudinal axis;   a second longitudinal side edge on a second side of the longitudinal axis:   a first elastic leg feature proximate to the first longitudinal side edge;   a second elastic leg feature proximate to the second longitudinal side edge;   a topsheet;   a backsheet;   an absorbent core positioned between the topsheet and the backsheet, wherein the absorbent core comprises:
 a first area of absorbent particulate polymer material, 
 a second area of absorbent particulate polymer material, and 
 a third area of absorbent particulate polymer material, 
   wherein the first area of absorbent particulate polymer material is concave relative to the longitudinal axis,   wherein the second area of absorbent particulate polymer material is concave relative to the longitudinal axis,   wherein the third area of absorbent particulate polymer material substantially surrounds the first area of absorbent particulate polymer material and the second area of absorbent particulate polymer material, and   wherein the first area of absorbent particulate polymer material has a first basis weight, wherein the second area of absorbent particulate polymer material has a second basis weight, and wherein the third area of absorbent particulate polymer material has a third basis weight, wherein the first basis weight is substantially the same as the second basis weight, and wherein the third basis weight is different than each of the first basis weight and the second basis weight.   
     
     
         14 . The absorbent article of  claim 13 , wherein the third basis weight varies in a direction parallel to the longitudinal axis. 
     
     
         15 . The absorbent article of  claim 13 , wherein the third basis weight varies in a direction perpendicular to the longitudinal axis. 
     
     
         16 . The absorbent article of  claim 13 , comprising an acquisition system disposed between the topsheet and the backsheet, wherein the acquisition system comprises one or more acquisition layers. 
     
     
         17 . The absorbent article of  claim 13 , wherein the absorbent core comprises:
 a first absorbent layer, wherein the first absorbent layer comprises:
 a first portion of absorbent particulate polymer material disposed on a first substrate; and 
 a first thermoplastic composition disposed on a portion of the first portion of absorbent particulate polymer material and a portion of the first substrate forming one or more land areas and junction areas; and 
   a second absorbent layer, wherein the first absorbent layer comprises:
 a second portion of absorbent particulate polymer material disposed on a second substrate; and 
 a second thermoplastic composition disposed on a portion of the second portion of absorbent particulate polymer material and a portion of the second substrate forming one or more land areas and junction areas. 
   
     
     
         18 . The absorbent article of  claim 17 , wherein the first absorbent layer is placed in facing relationship with the second absorbent layer. 
     
     
         19 . The absorbent article of  claim 12 , comprising a fastening member disposed in the first waist region, wherein the fastening member is configured to attach to a portion of the second waist region. 
     
     
         20 . The absorbent article of  claim 12 , comprising:
 a fastening member disposed in the first waist region;   a landing zone disposed on a garment facing surface of the absorbent article,   wherein the fastening member is configured to attach to a portion of the landing zone.   
     
     
         21 . The absorbent article of  claim 12 , wherein the first area of absorbent particulate polymer material has a first width and the second area of absorbent particulate polymer material has a second width,
 wherein the first width and the second width are the same,   wherein the first area of absorbent particulate polymer material has a first length and the second area of absorbent particulate polymer material has a second length,   wherein the first length and the second length are the same, and   wherein the first width and the second width are measured perpendicular to the longitudinal axis and the first length and the second length are measured parallel to the longitudinal axis.   
     
     
         22 . The absorbent article of  claim 12 , wherein the first area of absorbent particulate polymer material has an arcuate shape, and wherein the second area of absorbent particulate polymer material has an arcuate shape. 
     
     
         23 . An absorbent article comprising:
 a lateral axis;   a longitudinal axis;   a front waist region on a first side of the lateral axis;   a back waist region on a second side of the lateral axis;   a first longitudinal side edge on a first side of the longitudinal axis;   a second longitudinal side edge on a second side of the longitudinal axis:   a first elastic leg feature proximate to the first longitudinal side edge;   a second elastic leg feature proximate to the second longitudinal side edge;   a topsheet;   a backsheet;   an absorbent core positioned between the topsheet and the backsheet, wherein the absorbent core comprises:
 a first area of absorbent particulate polymer material, 
 a second area of absorbent particulate polymer material, and 
 a third area of absorbent particulate polymer material, 
   wherein the first area of absorbent particulate polymer material extends in a direction substantially parallel with the longitudinal axis and is disposed on a first side of the longitudinal axis,   wherein the second area of absorbent particulate polymer material extends in a direction substantially parallel to the longitudinal axis and is disposed on the second side of the longitudinal axis,   wherein the third area of absorbent particulate polymer material substantially surrounds each of the first area of absorbent particulate polymer material and the second area of absorbent particulate polymer material, and   wherein the first area of absorbent particulate polymer material has a first basis weight, the second area of absorbent particulate polymer material has a second basis weight, and the third area of absorbent particulate polymer material has a third basis weight, and wherein the third basis weight is different than each of the first basis weight and the second basis weight.   
     
     
         24 . The absorbent article of  claim 23 , wherein the third basis weight varies in a direction parallel to the longitudinal axis and/or perpendicular to the longitudinal axis. 
     
     
         25 . The absorbent article of  claim 23 , wherein the third area of absorbent particulate polymer material is disposed between the first area of absorbent particulate polymer material and the first longitudinal side edge, between the first area of absorbent particulate polymer material and the second area of absorbent particulate polymer material, and between the second area of absorbent particulate polymer material and the second longitudinal side edge.