Assembled intermediate comprising staple fiber nonwoven web and articles

Abstract

An assembled intermediate is described comprising a fluid transport element proximate an absorbent material is described. The fluid transport element comprises a thermoplastic nonwoven web comprising a plurality of bonded staple fibers having an average diameter of 20 to 500 microns, a thickness of at least 3, and a density ranging from 0.01 to 0.10 g/cm 3 . Also described are articles comprising such assembled intermediate.

What is claimed is: 
     
         1 . An assembled intermediate consisting of a thermoplastic nonwoven web prepared from a hydrophobic polymer proximate an absorbent material; wherein the nonwoven web consists of a plurality of bonded staple fibers having an average diameter of 20 to 500 microns and the nonwoven web has a thickness of at least 3 mm, a density ranging from 0.01 to 0.06 g/cm 3 , and a work of compression no greater than 20 kJ/m 3 ; and the nonwoven web is free of hydrophilic fibers and superabsorbent polymer such that the nonwoven web exhibits a vertical wicking of saline solution of no greater than 5 mm. 
     
     
         2 . The assembled intermediate of  claim 1  wherein the staple fibers have an average diameter of no greater than 200 microns. 
     
     
         3 . The assembled intermediate of  claim 1  wherein the nonwoven web has a work of compression of no greater than 20 kJ/m 3 . 
     
     
         4 . The assembled intermediate of  claim 3  wherein the nonwoven web has a work of compression of no greater than 15 kJ/m 3 . 
     
     
         5 . The assembled intermediate of  claim 1  wherein the nonwoven web has a basis weight ranging from 100 gsm to 400 gsm. 
     
     
         6 . The assembled intermediate of  claim 1  wherein the nonwoven web has a basis weight less than 300 gsm. 
     
     
         7 . The assembled intermediate of  claim 1  wherein the nonwoven web has a thickness no greater than 10 mm. 
     
     
         8 . The assembled intermediate of  claim 1  wherein the nonwoven web exhibits any one or combination of fluid transport rate properties selected from
 a fluid transport rate of no greater than 15 seconds with a weight of 4 kg; 
 a fluid transport rate of no greater than 30 seconds with a weight of 12 kg; and 
 a fluid transport rate of no greater than 60 seconds with a weight of 24 kg. 
 
     
     
         9 . The assembled intermediate of  claim 1  wherein all the lateral edges of the nonwoven web are in contact with the absorbent material. 
     
     
         10 . The assembled intermediate of  claim 1  wherein the absorbent material comprises cellulosic fibers and superabsorbent polymer. 
     
     
         11 . The assembled intermediate of  claim 10  wherein the assembled intermediate exhibits any one or combination of fluid uptake rate properties selected from
 a fluid uptake rate of no greater than 10 seconds with a weight of 4 kg; and 
 a fluid uptake rate of no greater than 30 seconds with a weight of 12 kg. 
 
     
     
         12 . The assembled intermediate of  claim 18  wherein the assembled intermediate exhibits any one or combination of length of longitudinal fluid distribution properties selected from
 a length of longitudinal fluid distribution of at least 100 mm with a weight of 4 kg; and 
 a length of longitudinal fluid distribution of at least 100 mm with a weight of 12 kg. 
 
     
     
         13 . The assembled intermediate of  claim 11  where the assembled intermediate exhibits the fluid uptake property with one or two fluid challenges. 
     
     
         14 . The assembled intermediate of  claim 1  wherein the nonwoven web has a thickness less than the assembled intermediate. 
     
     
         15 . The assembled intermediate of  claim 1  wherein the nonwoven web has a thickness ranging up to about 20 mm. 
     
     
         16 . The assembled intermediate of  claim 1  wherein openings between bonded staple fibers form an open network of macropores. 
     
     
         17 . An absorbent article comprising the absorbent assembled intermediate of  claim 1 , wherein the article is not a personal hygiene article. 
     
     
         18 . The absorbent article of  claim 17  wherein the absorbent article is a wound dressing. 
     
     
         19 . The absorbent article of  claim 17  wherein the absorbent article is for medical use. 
     
     
         20 . The absorbent article of  claim 17  wherein the absorbent article is for spill containment use.