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  Core for absorbent articles and method of making the sameUSPTO Application #: 20060040579Title: Core for absorbent articles and method of making the same Abstract: An absorbent core is provided for use in an absorbent article. The core includes a plurality of substantially continuous and coextensive filaments. At least some of the filaments have disposed on a surface thereof a layer comprising a superabsorbent material formed in place on the surface from a liquid superabsorbent polymer. (end of abstract) Agent: Ratnerprestia - Valley Forge, PA, US Inventors: Donald A. Sheldon, Frank S. Glaug USPTO Applicaton #: 20060040579 - Class: 442366000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Nonwoven Fabric (i.e., Nonwoven Strand Or Fiber Material), Including Parallel Strand Or Fiber Material Within The Nonwoven Fabric The Patent Description & Claims data below is from USPTO Patent Application 20060040579. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE INVENTION [0001] This invention relates to absorbent articles. More particularly, it relates to absorbent cores for absorbent articles wherein the core comprises an expanded tow having on its surface a superabsorbent polymer. BACKGROUND OF THE INVENTION [0002] The use of absorbent articles, such as protective undergarments, has increased steadily for many years. Early uses, such as diapers for babies and sanitary products for women, have in recent years been joined by an increasing demand for products designed to deal with incontinence issues for adults, frequently brought on by advanced age, obesity, or a variety of medical conditions. At the same time, markets have grown in all of these areas for both disposable and reusable products, depending on the preferences of the consumer. [0003] Currently available absorbent articles usually include superabsorbent polymers (SAP). These materials are capable of absorbing a large quantity of body fluid, such as urine, blood, and menses, and thus have become the standard for absorbent articles for hygiene purposes. [0004] One example of the use of SAP is described in U.S. Pat. No. 5,641,561 to Hansen et al. There are described absorbent composites made of fibrous material (e.g. cellulosic or synthetic material) and particulate superabsorbent polymers that are bound to the fiber via hydrogen bonding binder molecules. Superabsorbent polymer particles are mixed as particles with bleached kraft fluff, heated and spread out to dry. The binder adheres the SAP particles to the fibers. The dried product is then fed through a hammermill and shunted to an airlay line to produce a web containing 40% SAP particles attached to individual fibers. [0005] U.S. Pat. No. 5,593,399 to Tanzer discloses an absorbent article, namely a diaper, having two layers attached by an adhesive to provide attached zones and unattached zones to form pocket regions. Tanzer describes the use of SAP particles located within the pocket regions of the article to provide an absorbent laminate. The pocket regions are arranged in a non-contiguous and labyrinth configuration. [0006] There is an ever-increasing demand for thinner absorbent articles that nonetheless have high fluid absorption capacity. Unfortunately, some conventional absorbent articles tend to be bulky. [0007] Whitmore et al., in U.S. Pat. No. 6,417,425, describe absorbent articles including an absorbent core and an acquisition layer designed to afford rapid uptake of fluid, good transfer properties, good uptake upon repeated insults with fluid, and good skin compatibility. The acquisition layer, which also has absorbent capabilities, is prepared by a process that includes spraying onto a fibrous web a blend containing superabsorbent polymer particles, superabsorbent-forming monomer, initiator and water, and subjecting the web to polymerization conditions. In the '425 patent, there is stated the belief that the absorbent structure performs well as an acquisition layer in a disposable diaper because the swelling of the superabsorbent polymer particles is capable of expanding the fibrous web, so that the interstitial pore volume of the web increases after an insult of liquid. [0008] Despite the foregoing developments, however, there remains a need for improved absorbent articles. SUMMARY OF THE INVENTION [0009] According to one aspect of the invention, an absorbent core is provided for use in an absorbent article. The core includes a plurality of substantially continuous and coextensive filaments, at least some of the filaments having disposed on a surface thereof a layer comprising a superabsorbent material formed in place on the surface from a liquid superabsorbent polymer. [0010] According to another aspect of the invention, a method of making an absorbent core for use in an absorbent article is provided. The method includes expanding a tow comprising a plurality of substantially continuous and coextensive filaments, each filament having a surface. The method also includes forming, from a liquid superabsorbent polymer, a layer comprising a superabsorbent material on the surface of at least some of the filaments. [0011] According to yet another aspect of the invention, a system is provided for making an absorbent core for use in an absorbent article. The system includes means for applying a liquid superabsorbent polymer to a tow comprising a plurality of substantially continuous and coextensive filaments, thereby forming a treated expanded tow comprising a liquid superabsorbent polymer coating on the surface of at least some of the filaments. Means is provided for forming, from the liquid superabsorbent polymer coating, a layer comprising a superabsorbent material on the surface of at least some of the filaments. BRIEF DESCRIPTION OF THE FIGURES [0012] FIG. 1 is a side view of an embodiment of a tow material configured to form a component of an absorbent core according to an aspect of this invention. [0013] FIG. 2 is a side view of the tow material shown in FIG. 1 after it has been expanded according to an aspect of this invention. [0014] FIG. 3 is a side view of the expanded tow material shown in FIG. 2 with treated and untreated filaments. [0015] FIG. 4 is a schematic representation of an embodiment of a system for forming an absorbent core according to an aspect of this invention. [0016] FIG. 5 is a schematic representation of another embodiment of a system for forming an absorbent core according to an aspect of this invention. DETAILED DESCRIPTION OF THE INVENTION [0017] Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention. [0018] In one exemplary aspect, the invention provides an absorbent core for use in an absorbent article. The core comprises a plurality of filaments in the form of an expanded tow, and a layer comprising a superabsorbent material on surfaces of the filaments. In another exemplary aspect, the invention provides method of making an absorbent core for use in an absorbent article. The method includes providing a tow comprising a plurality of filaments, partially separating the filaments to afford an expanded tow, and providing a layer comprising a superabsorbent material on surfaces of the filaments. [0019] Absorbent cores according to one exemplary embodiment of the invention may find particular utility in the preparation of absorbent articles such as protective undergarments. These may include, for example, protective underwear, training pants, adult briefs, diapers, incontinence pads, and feminine hygiene pads. The absorbent articles may be disposable, or the cores may be disposable items removably incorporated in re-usable articles. Continue reading... Full patent description for Core for absorbent articles and method of making the same Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Core for absorbent articles and method of making the same patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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