# US 2019/0314221 A1 · Pulpless absorbent core and method of core forming > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0314221 A1 - Document ID: US20190314221A1 - Status: Published application - Kind: A1 - Application number: 16/454,301 - Filed: 2019-06-27 - Published: 2019-10-17 - Earliest claimed: 2014-07-30 - Assignees: Curt G. Joa, Inc. - Applicants: Curt G. Joa, Inc. - Inventors: Wei Wei; Gottfried Jason Hohm - Web page: https://patentgrep.com/patent/US20190314221A1 ## CPC - A61F 13/5323: {having absorbent material located in discrete regions, e.g. pockets} - B32B 37/0053: {Constructional details of laminating machines comprising rollers; Constructional features of the rollers} - B32B 37/1292: {selectively, e.g. in stripes, in patterns (B32B37/0076 takes precedence)} - B32B 37/14: characterised by the properties of the layers - B32B 38/1825: {characterised by the control or constructional features of devices for tensioning, stretching or registration} - B32B 38/1841: {during laying up} - A61F 13/49017: {the elastic means being located at the crotch region} - A61F 2013/530554: {and being fixed to a web} - B32B 2307/51: Elastic - B32B 2307/726: Permeability to liquids, absorption - 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) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM ## Abstract A pulpless core is provided with flexibility for superabsorbent expansion by using elastic strands stretched and coupled to a nonwoven layer, and then relaxed partially to create receiving valleys (puckers) and the puckers are provided with superabsorbent polymer, and then a layer of nonwoven or acquisition film can be coupled on top of nonwoven/elastic/sap carrier layers to create an absorbent core laminate. ## Claims ### Claim 1 A method of forming an absorbent core, the method comprising: providing a first material layer; coupling elastic strands to the first material layer at a first tension to form an elastic and material layer combination; performing a first tension let-off to partially relax the elastic strands to a second tension that is less than the first tension, wherein the partial relaxing of the elastic strands to the second tension deforms the first material layer to form a plurality of valleys in the first material layer; applying a superabsorbent polymer material onto the first material layer; and securing a second material layer to the elastic and material layer combination to capture the superabsorbent polymer material in the plurality of valleys. ### Claim 2 (depends on 1) The method of claim 1 performing a second tension let-off to partially relax the elastic strands to a third tension that is less than the first tension and the second tension, wherein the partial relaxing of the elastic strands to the third tension creates a continuous web of superabsorbent polymer material in the absorbent core. ### Claim 3 (depends on 1) The method of claim 1 wherein the superabsorbent polymer material is applied when the first material layer is moving in a machine direction. ### Claim 4 (depends on 1) The method of claim 1 wherein coupling the elastic strands to the first material layer and securing the second material layer to the elastic and material layer combination comprises adhering the elastic strands to the first material layer and adhering the second material layer to the elastic and material layer combination, with a pattern of adhesive on the second material layer matching a pattern of the elastic strands on the first material layer. ### Claim 5 (depends on 1) The method of claim 1 wherein applying the superabsorbent polymer material onto the first material layer comprises applying the superabsorbent polymer material in a plurality of lanes defined by adjacent pairs of elastic strands. ### Claim 6 (depends on 5) The method of claim 5 wherein the plurality of lanes of the superabsorbent polymer material are applied intermittently to form gaps in the superabsorbent polymer material extending in the machine direction. ### Claim 7 (depends on 1) The method of claim 1 further comprising urging the second material layer into contact with the elastic and material layer combination via a ridged nip wheel, the ridged nip wheel including wheel peaks and wheel valleys, wherein the superabsorbent polymer material migrates into the wheel valleys as the second material layer is pressed into contact with the elastic and material layer combination. ### Claim 8 (depends on 1) The method of claim 1 wherein coupling the elastic strands to the first material layer comprises one of: coupling elastic strands to the first material layer such that the elastic strands are parallelly aligned and spaced apart in the machine direction; coupling elastic strands to the first material layer such that the elastic strands are parallelly aligned and spaced apart in a cross-machine direction; or coupling elastic strands to the first material layer such that the elastic strands are in a curved pattern and oriented generally in the machine direction. ### Claim 9 A stretchable absorbent core formed by a process comprising: providing a first material layer; coupling elastic strands under tension to the first material layer to form an elastic and material layer combination; performing a first tension let-off to partially relax the elastic strands, wherein the partial relaxing of the elastic strands deforms the first material layer to form a plurality of valleys in the first material layer; applying a superabsorbent polymer material onto the first material layer; and securing a second material layer to the elastic and material layer combination to capture the superabsorbent polymer material in the plurality of valleys ### Claim 10 (depends on 9) The stretchable absorbent core of claim 9 formed by a process comprising performing a second tension let-off to further relax the elastic strands to a lower tension, wherein the further relaxing of the elastic strands to the lower tension creates a continuous web of superabsorbent polymer material in the absorbent core. ### Claim 11 (depends on 9) The stretchable absorbent core of claim 9 formed by a process comprising adhering the elastic strands to the first material layer and adhering the second material layer to the elastic and material layer combination, with a pattern of adhesive on the second material layer matching a pattern of the elastic strands on the first material layer. ### Claim 12 (depends on 9) The stretchable absorbent core of claim 9 formed by a process comprising applying the superabsorbent polymer material in a plurality of lanes defined by adjacent pairs of elastic strands. ### Claim 13 (depends on 13) The stretchable absorbent core of claim 13 wherein the plurality of lanes of the superabsorbent polymer material are applied intermittently to form gaps in the superabsorbent polymer material extending in the machine direction. ### Claim 14 (depends on 9) The stretchable absorbent core of claim 9 formed by a process comprising urging the second material layer into contact with the elastic and material layer combination via a ridged nip wheel, the ridged nip wheel including wheel peaks and wheel valleys, wherein the superabsorbent polymer material migrates into the wheel valleys as the second material layer is pressed into contact with the elastic and material layer combination. ### Claim 15 (depends on 9) The stretchable absorbent core of claim 9 formed by a process comprising one of: coupling elastic strands to the first material layer such that the elastic strands are parallelly aligned and spaced apart in the machine direction; coupling elastic strands to the first material layer such that the elastic strands are parallelly aligned and spaced apart in a cross-machine direction; or coupling elastic strands to the first material layer such that the elastic strands are in a curved pattern and oriented generally in the machine direction. ### Claim 16 A stretchable absorbent core comprising: a first material layer; a series of elastic strand members coupled to the first material layer at a partially tensioned state that deforms the first material layer to form a plurality of valleys therein; a second material layer coupled to the elongated elastic strand members and over the first material layer; and a superabsorbent polymer material positioned in the plurality of valleys and between the first material layer and the second material layer, so as to be captured in the plurality of valleys. ### Claim 17 (depends on 16) The stretchable absorbent core of claim 16 wherein the series of elastic strand members comprise elongated, linear elastic strands.