Multi-layer absorbent cores and methods of manufacture

An absorbent garment extending in a longitudinal and a lateral direction and comprising:

• a bodyside liner;
• an outer cover;
• an absorbent body disposed between the bodyside liner and the outer cover, the absorbent body comprising:
• a top facing material layer,
• a bottom facing material layer,
• a lofty nonwoven reinforcing material disposed between the top facing material layer and the bottom facing material layer the lofty nonwoven material being a through-air bonded carded web (TABCW) material having a basis weight of between 15 gsm and about 60 gsm and made of polyolefin fibers,
• absorbent material comprising superabsorbent material forming a plurality of spaced superabsorbent material lanes disposed between the top facing material layer and the bottom facing material layer and within the reinforcing material,
• wherein a first side portion of the absorbent body and a second side portion of the absorbent body are folded onto a central portion of the absorbent body forming a folded absorbent body with a first folded portion and a second folded portion with a channel region disposed between the first folded portion and the second folded portion and wherein there is no overlap between superabsorbent lanes in the first folded portion or the second folded portion, and
• wherein the superabsorbent material lanes spaced from apart by a of distance between 5 mm and 15 mm and a combined width of the superabsorbent material lanes comprises between 40% and 60% of an overall width of the folded absorbent body;
• and
• an acquisition material disposed between the absorbent body and the bodyside liner, wherein the acquisition material spans across the channel region and is bonded into the channel.

A method of forming an absorbent garment, the method comprising:

• moving a first facing material in a machine direction;
• moving a reinforcing material in the machine direction, the reinforcing material having a first side and a second side, the reinforcing material being a through-air bonded carded web (TABCW) material having a basis weight of between 15 gsm and about 60 gsm and made of polyolefin fibers;
• applying superabsorbent material to the first side of the reinforcing material, the first side of the reinforcing material facing up in a vertical direction, the superabsorbent material being applied in a first series of spaced apart lanes;
• reversing an orientation of the reinforcing material so that the first side of the reinforcing material faces down in the vertical direction;
• applying the first side of the reinforcing material to the first facing material;
• applying superabsorbent material to the second side of the reinforcing material, the superabsorbent material being applied in a second series of spaced apart lanes, wherein the first series of spaced apart lanes and the second series of spaced apart lanes overlap to form regions within the reinforcing material containing superabsorbent material and regions in the reinforcing material devoid of superabsorbent material;
• moving a second facing material in the machine direction;
• applying the second facing material to the second side of the reinforcing material to form an absorbent laminate comprising the first facing material, the reinforcing material, and the second facing material;
• folding a first side portion and a second side portion of the absorbent laminate onto a central portion of the absorbent laminate, the first side portion and the second side portion folded onto the central portion to form a channel region in the folded absorbent laminate, wherein there is no overlap between regions containing superabsorbent material in the first side portion and the central portion and no overlap between regions containing superabsorbent material in the second side portion and the central portion;
• moving an acquisition material in the machine direction;
• coupling the acquisition material to the folded absorbent laminate such that the acquisition material spans across the channel region;
• coupling the folded absorbent laminate and the acquisition material between a bodyside liner material and an outer cover material to form an absorbent garment.