Absorbent article with superabsorbent particle containing insert pad and liquid dispersion pad

An absorbent article comprising:

• a liquid impermeable backing sheet;
• a relatively liquid permeable facing sheet;
• a composite absorbent pad positioned between the backing sheet and the facing sheet, the composite pad comprising a liquid dispersion pad and a substantially bonded insert pad;
• the liquid dispersion pad comprising fibers and assisting in dispersing liquid passing through the facing sheet;
• and
• the insert pad including fibers at least partially coated with a binder material, the fibers being bound together by the binder material to form the substantially bonded insert pad, the fibers also having superabsorbent particles adhered to the fibers by the binder material, the insert pad having a dry weight, the superabsorbent particles being present in a range of from about ten percent to about eighty percent of the dry weight of the insert pad;
• the insert pad being positioned between the facing sheet and the liquid dispersion pad, the insert pad having a major surface which is not overlaid by the liquid dispersion pad so as to receive liquid passing through the facing sheet and wherein the fibers at least partially coated with the binder material are continuously coated with a thermoplastic binder material and in which the insert pad is thermobonded.

A disposable diaper comprising:

• a liquid impermeable backing sheet;
• a relatively liquid permeable facing sheet;
• a liquid dispersion pad comprised of fibers positioned between the backing and facing sheets, the liquid dispersion pad having a density from about 0.05 grams per cubic centimeter to about 0.15 grams per cubic centimeter, the liquid dispersion pad also having a basis weight of from about 150 grams per square meter to about 350 grams per square meter;
• and
• a densified bonded insert pad positioned between the dispersion pad and facing sheet, the insert pad having a major surface which is not overlaid by the liquid dispersion pad so as to receive liquid passing through the facing sheet, the insert pad comprising fibers at least partially coated with a thermoplastic binder material, the insert pad being heat bonded with the binder material interconnecting the fibers, the fibers also having superabsorbent particles adhered thereto by the binder material, the superabsorbent particles being present in an amount of from approximately ten to eighty percent by dry weight of the insert pad, the insert pad being densified to a density of from about 0.05 grams per cubic centimeter to about 0.3 grams per cubic centimeter, and the insert pad having a basis weight of from about 250 to about 800 grams per square meter.

A disposable diaper for use by a user with a front and back comprising:

• a liquid impermeable backing sheet;
• a relatively liquid permeable facing sheet;
• a liquid dispersion pad having an area and a length and being comprised of fibers, the dispersion pad being positioned between the backing and facing sheets, the liquid dispersion pad having a density of from about 0.08 grams per cubic centimeter to about 0.13 grams per cubic centimeter;
• a substantially bonded insert pad positioned between the facing sheet and the liquid dispersion pad, the insert pad including fibers substantially continuously coated with a thermoplastic containing binder material, the fibers being thermobonded together by the binder material to form a substantially bonded insert pad, the fibers also having superabsorbent particles adhered to the fibers by the binder material, the insert pad having a dry weight, the superabsorbent particles being present in a range of from about forty percent to about sixty percent of the dry weight of the insert pad, the insert pad being densified to a density of from about 0.18 grams per cubic centimeter to about 0.22 grams per cubic centimeter;
• the disposable diaper having a top front portion positioned against the from of the user when worn and a back portion positioned against the back of the user when worn, the liquid dispersion pad having a surface area and a length which is substantially co-extensive in length with the front and back portions of the disposable diaper, the insert pad having a surface area sized smaller than the surface area of the liquid dispersion pad, the insert pad overlying approximately twenty to eighty percent of the surface area of the liquid dispersion pad with the insert pad being positioned toward the front portion of the disposable diaper, the liquid dispersion pad and the insert pad each having respective side edges, at least one side edge of the insert pad being spaced inwardly from the side edges of the liquid dispersion pad, and in which the insert pad extends approximately no more than about three-quarters of the length of the liquid dispersion pad.