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  Absorbent structure with aggregate clustersUSPTO Application #: 20060141891Title: Absorbent structure with aggregate clusters Abstract: An absorbent structure has a macro absorbent structure with a plurality of aggregate clusters intermixed therein. The aggregate clusters have a periphery, an interior, and thermoplastic binder fibers. The thermoplastic binder fibers have thermoplastic binder fiber ends. The thermoplastic binder fiber ends are located at the periphery of the aggregate clusters. The interior of the aggregate clusters are substantially free of thermoplastic binder fiber ends. The macro absorbent structure and the aggregate clusters may also include thermoplastic binder fibers, staple fibers, superabsorbent particles and the like. A method of making absorbent structures includes a first absorbent structure, dividing the first absorbent structure to create aggregate clusters, providing a stream of the aggregate clusters, providing polymeric fibers, merging the aggregate cluster stream and polymeric fiber stream into a single product stream, and making a second absorbent structure. The method may further include staple fibers, superabsorbent particles, and the like. (end of abstract) Agent: Kimberly-clark Worldwide, Inc. - Neenah, WI, US Inventors: Shannon Kathleen Melius, Jeffrey Mark La Fortune, Michael John Faulks, David Arthur Fell, Michael Barth Venturino USPTO Applicaton #: 20060141891 - Class: 442416000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Nonwoven Fabric (i.e., Nonwoven Strand Or Fiber Material), Containing At Least Two Chemically Different Strand Or Fiber Materials, Containing Polymeric And Natural Strand Or Fiber Materials The Patent Description & Claims data below is from USPTO Patent Application 20060141891. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] Disposable absorbent articles are used for a variety of applications including disposable diapers, training pants, disposable swim pants, adult incontinence garments, feminine hygiene products, wound dressings, nursing pads, bed pads, wipes, bibs, wound dressings, surgical capes or drapes, and the like. Such disposable absorbent products are generally suited to absorb many substances such as water and body exudates such as urine, menses, blood, and the like. [0002] Some disposable absorbent articles are formed from densified cellulose intermixed with superabsorbent particles. Others are formed from high integrity absorbent structures containing high concentrations of superabsorbent particles entangled or otherwise commingled with long thermoplastic fibers and/or cellulosic fibers to improve fit, comfort, and/or performance. In general, the absorbent structures may be mechanically constrained or limited, particularly the high integrity structures, in such a way that the absorbent structure is not able to fully expand in the presence of liquids. Additionally, the high integrity absorbent structures may be expensive due to the addition of thermoplastic fibers. [0003] Therefore, there exists a need for absorbent structures, including high integrity absorbent structures, that can expand more fully in the presence of liquids and are more cost effective to manufacture. SUMMARY OF THE INVENTION [0004] In response to the discussed needs, the present invention provides absorbent structures with aggregate clusters and methods of making absorbent structures with aggregate clusters. [0005] In various embodiments, an absorbent structure includes a macro absorbent structure. The macro absorbent structure includes a plurality of aggregate clusters intermixed within the macro absorbent structure. The aggregate clusters have a periphery and an interior and include thermoplastic binder fibers having thermoplastic binder fiber ends. The thermoplastic binder fiber ends are located at the periphery of the aggregate clusters. [0006] The interiors of the aggregate clusters are substantially free of thermoplastic binder fiber ends. The macro absorbent structure includes long thermoplastic binder fibers and superabsorbent particles constrained within the long thermoplastic binder fibers. In these embodiments, the aggregate clusters may include superabsorbent particles constrained within the thermoplastic binder fibers within the aggregate clusters, staple fibers constrained within the thermoplastic binder fibers within the aggregate clusters, or both superabsorbent particles and staple fibers constrained within the thermoplastic binder fibers within the aggregate clusters. [0007] In various other embodiments, an absorbent structure includes a macro absorbent structure. The macro absorbent structure includes a plurality of aggregate clusters intermixed within the macro absorbent structure. The aggregate clusters have a periphery and an interior and include thermoplastic binder fibers have thermoplastic binder fiber ends. The thermoplastic binder fiber ends are located at the periphery of the aggregate clusters. The interiors of the aggregate clusters are substantially free of thermoplastic binder fiber ends. The macro absorbent structure includes long thermoplastic binder fibers and staple fibers constrained within the long thermoplastic binder fibers. In these embodiments, the aggregate clusters may include superabsorbent particles constrained within the thermoplastic binder fibers within the aggregate clusters, staple fibers constrained within the thermoplastic binder fibers within the aggregate clusters, or both superabsorbent particles and staple fibers constrained within the thermoplastic binder fibers within the aggregate clusters. [0008] In yet other embodiments, an absorbent structure includes a macro absorbent structure. The macro absorbent structure includes a plurality of aggregate clusters intermixed within the macro absorbent structure. The aggregate clusters have a periphery and an interior and include thermoplastic binder fibers having thermoplastic binder fiber ends. The thermoplastic binder fiber ends are located at the periphery of the aggregate clusters. The interiors of the aggregate clusters are substantially free of thermoplastic binder fiber ends. The macro absorbent structure includes long thermoplastic binder fibers, superabsorbent particles constrained within the long thermoplastic binder fibers, and staple fibers constrained within the long thermoplastic binder fiber. In these embodiments, the aggregate clusters may include superabsorbent particles constrained within the thermoplastic binder fibers within the aggregate clusters, staple fibers constrained within the thermoplastic binder fibers within the aggregate clusters, or both superabsorbent particles and staple fibers constrained within the thermoplastic binder fibers within the aggregate clusters. [0009] In yet other embodiments, an absorbent structure includes a macro absorbent structure. The macro absorbent structure includes a plurality of aggregate clusters intermixed within the macro absorbent structure. The aggregate clusters have a periphery and an interior and include thermoplastic binder fibers having thermoplastic binder fiber ends. The thermoplastic binder fiber ends are located at the periphery of the aggregate clusters. The interiors of the aggregate clusters are substantially free of thermoplastic binder fiber ends. The macro absorbent structure includes staple fibers and superabsorbent particles intermixed with the staple fibers. In these embodiments, the aggregate clusters may include superabsorbent particles constrained within the thermoplastic binder fibers within the aggregate clusters, staple fibers constrained within the thermoplastic binder fibers within the aggregate clusters, or both superabsorbent particles and staple fibers constrained within the thermoplastic binder fibers within the aggregate clusters. [0010] In various embodiments, the aggregate clusters may have a greatest dimension of 0.5 mm to 20 mm and/or a weight percent of 20 to 50 percent. In various embodiments, the long thermoplastic binder fibers are elastic. [0011] In one embodiment, a stabilized absorbent structure includes 5 to 50 weight percent meltblown polyolefin binder fibers having an average fiber length greater than 1 cm. The stabilized absorbent structure also has 1 to 50 weight percent cellulose fibers constrained within the polyolefin binder fibers. The stabilized absorbent structure also has 30 to 90 weight percent superabsorbent particles constrained within the polyolefin binder fibers. The stabilized absorbent structure also has 1 to 50 weight percent aggregate clusters. Each aggregate cluster has a periphery and an interior. The aggregate clusters include meltblown polyolefin binder fibers having meltblown polyolefin binder fiber ends. The aggregate clusters further include cellulose fibers constrained within the polyolefin binder fibers within the aggregate clusters. The aggregate clusters further include superabsorbent particles constrained in the polyolefin binder fibers within the aggregate clusters. The meltblown polyolefin binder fiber ends are located at the periphery of the aggregate clusters. The interiors of the aggregate clusters are substantially free of meltblown polyolefin binder fiber ends. [0012] In another aspect, the present invention provides a method of making a stabilized absorbent structure. The method includes providing a first absorbent structure. The first absorbent structure includes long thermoplastic binder fibers. The method further includes dividing the first absorbent structure into aggregate clusters. The aggregate clusters are provided as a stream of aggregate clusters. The method includes providing a stream of extruded molten thermoplastic polymeric fibers. The aggregate clusters stream and the polymeric fiber stream are merged into a single product stream. The single product stream is collected on a forming surface to make a second stabilized absorbent structure including aggregate clusters. In various embodiments, the second stabilized absorbent structure including aggregate clusters may be used to produce a disposable absorbent article. [0013] In various embodiments, the process further includes merging a stream of superabsorbent particles into the aggregate clusters stream, the polymeric fiber stream, or the single product stream. [0014] In various embodiments, the process further includes merging a stream of wood pulp fibers into the aggregate cluster stream, the polymeric fiber stream, or the single product stream. BRIEF DESCRIPTION OF THE DRAWINGS [0015] FIG. 1 representatively illustrates a perspective view of an exemplary absorbent article according to the present invention; [0016] FIG. 2A representatively illustrates a cross-sectional view of a first alternative embodiment of the absorbent article of FIG. 1 taken along the line 2-2; [0017] FIG. 2B representatively illustrates a cross-sectional view of a second alternative embodiment of the absorbent article of FIG. 1 taken along the line 2-2; [0018] FIG. 3A is a light photomicrograph image of an exemplary macro absorbent structure containing aggregate clusters according to the present invention; [0019] FIG. 3B is a Scanning Electron Micrograph image of a portion of the exemplary macro absorbent structure of FIG. 3A; [0020] FIG. 4 is a Scanning Electron Micrograph image of an exemplary aggregate cluster according to the present invention; [0021] FIG. 4A is a Scanning Electron Micrograph image of a cut thermoplastic binder fiber end; Continue reading... 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