# US 10,864,121 B2 · Method of making an absorbent composite and absorbent articles employing the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,864,121 B2 - Document ID: US10864121B2 - Status: Granted - Kind: B2 - Application number: 15/584,675 - Filed: 2017-05-02 - Published: 2017-10-19 - Granted: 2020-12-15 - Earliest claimed: 2006-02-22 - Assignees: DSG Technology Holdings Ltd. - Applicants: Dsg Technology Holdings Ltd. - Inventors: Patrick King Yu Tsang; Kuo-Shu Edward Chang; Andrew C. Wright - Web page: https://patentgrep.com/patent/US10864121B2 ## CPC - A61F 13/539: characterised by the connection of the absorbent layers with each other or with the outer layers - A61F 13/15658: {Forming continuous, e.g. composite, fibrous webs, e.g. involving the application of pulverulent material on parts thereof} - A61F 13/15699: {Forming webs by bringing together several webs, e.g. by laminating or folding several webs, with or without additional treatment of the webs} - A61F 13/49426: {the barrier having an absorbent medium} - A61F 13/51405: {treated or coated, e.g. with moisture repellent agent} - A61F 13/51478: {being a laminate, e.g. multi-layered or with several layers} - A61F 13/5323: {having absorbent material located in discrete regions, e.g. pockets} - A61F 13/536: having discontinuous areas of compression - A61F 13/15577: {Apparatus or processes for manufacturing} - A61F 13/15764: {Transferring, feeding or handling devices; Drives} - A61F 2013/530554: {and being fixed to a web} - A61F 2013/530562: {being arranged in discontinuous pattern} - A61F 2013/530671: {being mixed with mineral or inert material, e.g. "introfying particles"} - A61F 2013/5307: {characterized by the quantity or ratio of superabsorbent material} - A61F 2013/5355: {with terraced core} - A61F 2013/53925: {with intermittent pattern, e.g. spots} - Y10T 156/10: Methods of surface bonding and/or assembly therefor - A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method of making an absorbent composite that includes a first fabric, a second fabric, and particles positioned between the two fabrics and absorbent articles made from the absorbent composite. The particles are secured between the two fabric using adhesive, thermal plastic or combinations thereof. The fabrics are bonded together in a manner that limits particle movement between the fabrics. The bond pattern may define pockets or other shapes. In applications in which the bond pattern forms pockets, the particles may be positioned in the pockets. The particles may be SAP particles or other particles with advantageous properties. ## Claims ### Claim 1 An absorbent composite comprising, a first fabric; a second fabric bonded to said first fabric along first bond sites; and absorbent particles secured between the first and second fabrics and limited in movement by said first fabric being bonded to said second fabric along said bond sites; and wherein said absorbent particles are superabsorbent particles (SAP) providing pulpless concentrations of absorbent material secured between the first and second fabrics; a third fabric; a fourth fabric bonded to said first fabric along second bond sites; second absorbent particles secured between the third fabric and fourth fabric, the third fabric being thermally or ultrasonically bonded to the fourth fabric to inhibit movement of said second absorbent particles; a fifth fabric; a sixth fabric bonded to said fifth fabric along third bond sites; and third absorbent particles secured between the fifth fabric and sixth fabric, the fifth fabric being thermally or ultrasonically bonded to the sixth fabric to inhibit movement of said third absorbent particles. ### Claim 2 (depends on 1) The absorbent composite of claim 1, wherein said absorbent particles are secured between said first fabric and said second fabric to provide, therebetween, concentrations of superabsorbent particles lacking an absorbent matrix, said absorbent composite further comprising a third fabric and second super absorbent particles secured between said third fabric and second fabric to provide, therebetween, concentrations of SAP lacking an absorbent matrix. ### Claim 3 (depends on 2) The absorbent composite of claim 2, wherein said bond sites of said bonding pattern form pockets within which super absorbent particles are secured. ### Claim 4 (depends on 3) The absorbent composite of claim 3, wherein said bond sites form a bonding pattern of rectangles. ### Claim 5 (depends on 1) The absorbent composite of claim 1, wherein said bond sites form a bonding pattern to secure said absorbent particles between said fabrics and inhibit particle migration. ### Claim 6 (depends on 1) The absorbent composite of claim 1, wherein a bonding pattern of bond sites bonds said first and second fabric together to secure, therebetween, the absorbent particles without an absorbent matrix, said bond sites forming pockets within which absorbent particles are positioned; and wherein loose absorbent particles are secured between said first fabric and said second fabric. ### Claim 7 (depends on 1) The absorbent composite of claim 1, wherein each said first, second, and third absorbent particles interposed between fabrics form a layer of superabsorbent particles lacking an absorbent matrix. ### Claim 8 (depends on 1) The absorbent composite of claim 1, wherein said first fabric is bonded to said second fabric to form pockets within which absorbent particle concentrations consisting of SAP are secured, the pockets inhibiting particle movement and forming a bonding pattern of rectangular pockets and wherein the bond sites are not aligned in a straight line to the lateral margins. ### Claim 9 (depends on 1) The absorbent composite of claim 1, wherein the second and third fabrics are positioned adjacent one another. ### Claim 10 (depends on 1) The absorbent composite of claim 1, wherein said bond sites form a plurality of pockets between the fabrics wherein absorbent particles are secured, wherein loose superabsorbent particles are secured between the fabrics. ### Claim 11 (depends on 1) The absorbent composite of claim 1, wherein said bond sites form a plurality of pockets between the fabrics and loose superabsorbent particles are secured between the fabrics. ### Claim 12 A disposable absorbent article comprising: a topsheet forming an inner surface; a backsheet forming an outer surface; an absorbent core interposed between said topsheet and said backsheet, said absorbent core including a first fabric; a second fabric bonded to the first fabric along bond sites; and absorbent particles secured between said first fabric and said second fabric to inhibit particle migration; wherein the absorbent particles are superabsorbent particles (SAP); wherein said absorbent core includes a first absorbent composite comprising said first fabric, said second fabric, and said absorbent particles secured therebetween, and a second absorbent composite comprising a third fabric, a fourth fabric, and second absorbent particles disposed therebetween, the third fabric being thermally or ultrasonically bonded to the fourth fabric to inhibit movement of said second absorbent particles, wherein said second composite is disposed adjacent said first absorbent composite and between said backsheet and said first absorbent composite; and wherein said absorbent core further includes a third absorbent composite disposed such that said second absorbent composite is disposed between said first absorbent composite and said third absorbent composite, and wherein, between pairs of fabrics of each absorbent composite, a layer consisting of superabsorbent particles lacking an absorbent matrix is disposed. ### Claim 13 (depends on 12) The absorbent article of claim 12, wherein, between said first fabric and said second fabric, said absorbent core includes one or more layers of concentrations of superabsorbent particles lacking an absorbent matrix. ### Claim 14 (depends on 12) The absorbent article of claim 12, wherein bond sites bond said first fabric to said second fabric to secure said absorbent particles therebetween, the bond sites forming a bonding pattern inhibiting migration of SAP. ### Claim 15 (depends on 14) The absorbent particle of claim 14, wherein said bonding pattern form pockets within which concentrations of SAP are positioned. ### Claim 16 (depends on 14) The absorbent article of claim 14, wherein said bond sites form a bonding pattern selected from the group of bonding patterns consisting of herringbone, bricklayer, circles, triangles, dots, dashes, rectangles, and combinations thereof. ### Claim 17 (depends on 14) The absorbent article of claim 14, wherein said bond sites form a bonding pattern of rectangles forming pockets wherein concentrations of SAP are positioned, the bonding pattern inhibiting migration of particles from said pockets. ### Claim 18 (depends on 14) The absorbent article of claim 14, wherein SAP are positioned as loose particles between said first layer and said second layer within said bonding pattern. ### Claim 19 (depends on 12) The absorbent article of claim 12, wherein, for each absorbent composite, bond sites bond one fabric n to the other fabric to form pockets within which SAP, lacking an absorbent matrix, is positioned; and wherein said bond sides are disposed about said pockets and form a bonding pattern, and wherein said superabsorbent particles are disposed between said fabrics as loose particles. ### Claim 20 (depends on 12) The absorbent article of claim 12, wherein said absorbent core includes multiple layers of superabsorbent particles disposed between layers of nonwoven, said layers of SAP having different concentrations of SAP. ### Claim 21 (depends on 12) The absorbent article of claim 12, wherein said SAP form a non-uniform layer of SAP wherein the SAP concentration varies. ### Claim 22 (depends on 12) The absorbent article of claim 12, wherein said superabsorbent particles are secured between said first fabric and said second fabric by adhesive. ### Claim 23 (depends on 12) The absorbent article of claim 12, wherein bond sites bond said first fabric to said second fabric to secure said absorbent particles therebetween, the bond sites forming a bonding pattern inhibiting migration of SAP and arranged relative to said absorbent particles to prevent straight line migration of more than 2 inches. ### Claim 24 (depends on 12) The absorbent article of claim 12, further comprising an acquisition layer positioned between said absorbent composite and said topsheet. ### Claim 25 (depends on 12) The absorbent article of claim 12, wherein said absorbent particles form a non-uniform layer, wherein concentrations of SAP are higher in a region corresponding to a crotch region of the article. ### Claim 26 (depends on 12) The absorbent composite of claim 12, wherein said bond sites form a plurality of pockets between the fabrics and loose superabsorbent particles are secured between the fabrics. ### Claim 27 An absorbent composite comprising: a first fabric; a second fabric bonded to said first fabric along first bond sites; and first absorbent particles positioned between the first and second fabric and limited in movement by said second fabric being bonded to said second fabric along said first bond sites, said absorbent particles lacking an absorbent matrix; and a third fabric disposed relative to said second fabric such that said second fabric is intermediate said third fabric and said first fabric; and second absorbent particles disposed intermediate the third fabric and the first absorbent particles and lacking an absorbent matrix, said third fabric being bonded to another fabric along second bond sites, the second bond sites inhibiting movement of said second absorbent particles. ### Claim 28 (depends on 27) The absorbent composite of claim 27, wherein said first and second bond sites form bonding patterns and a plurality of pockets within which super absorbent particles are disposed, the bond sites inhibiting movement of said super absorbent particles in said pockets. ### Claim 29 (depends on 28) The absorbent composite of claim 28, wherein said another fabric is said second fabric and said third fabric is bonded to said second fabric along said bond sites. ### Claim 30 (depends on 28) The absorbent composite of claim 28, wherein said another fabric is a fourth fabric independent of said second fabric; and wherein said first and second fabrics and said first absorbent particles form a first absorbent sheet, and said third fabric, said fourth fabric and said second absorbent particles form a second absorbent sheet, said first and second absorbent sheets being laminated together of form a multi-layer absorbent composite structure. ### Claim 31 (depends on 28) The absorbent composite of claim 28, wherein said first absorbent particles form a first layer of super absorbent particles and said second absorbent particles form a second layer of super absorbent particles, wherein concentrations of SAP vary between said first absorbent particles and said second absorbent particles. ### Claim 32 (depends on 31) The absorbent composite of claim 31, wherein one of said first and second layers has a non-uniform layer of SAP including a zone of high SAP concentration, and the other of said first and second layers has a uniform layer of SAP. ### Claim 33 The absorbent composite of 31, wherein each said layer of absorbent particles include a zone of higher SAP concentration, the zones of higher SAP concentration together providing an area of high SAP concentration. ### Claim 34 (depends on 28) The absorbent composite of claim 28, wherein said bond sites are thermal bond sites or ultrasonic bond sites bonding said fabrics and forming a bonding pattern defining spaced apart pockets of SAP particles and inhibiting movement of SAP particles; and wherein the bond sites are arranged to prevent straight line particle migration of more than two inches. ### Claim 35 (depends on 28) The absorbent composite of claim 28, wherein said another fabric is said second fabric, and wherein said first, second, and third fabrics are mutually bonded along bond sites extending therethrough. ### Claim 36 (depends on 28) The absorbent composite of claim 28, wherein said bonding pattern form a pattern of rectangle pockets within which super absorbent particles are disposed. ### Claim 37 (depends on 28) The absorbent composite of claim 28, wherein said absorbent particles are SAP secured, at least partly, between fabrics by adhesive. ### Claim 38 (depends on 27) The absorbent composite of claim 27, wherein loose superabsorbent particles are secured between the fabrics and said bond sites form a plurality of pockets between the fabrics within which said superabsorbent particles are positioned.