Process for making absorbent material with in-situ polymerized superabsorbent

A process for making an absorbent composite nonwoven web, comprising the steps of:

• forming a first plurality of thermoplastic fibers using a first extrusion apparatus;
• providing a first primary gas stream which carries the first plurality of thermoplastic fibers away form the extrusion apparatus;
• providing a first secondary gas stream carrying a first plurality of absorbent fibers;
• combining the first primary gas stream and the first secondary gas stream to form an integrated stream including a mixture of the thermoplastic fibers and the absorbent fibers;
• providing a first superabsorbent polymer precursor composition;
• chemically reacting the superabsorbent polymer precursor composition to form a superabsorbent polymer within the mixture;
• depositing the mixture onto a forming surface;
• and
• forming the absorbent composite nonwoven web from the mixture.

A process for making an absorbent composite nonwoven web, comprising the steps of:

• providing a first superabsorbent polymer precursor composition including a monomer;
• providing a second superabsorbent polymer precursor composition including a polymerization initiator;
• providing at least one stream carrying a plurality of cellulose fibers;
• combining the first and second superabsorbent polymer precursor compositions with the cellulose fibers to form a mixture;
• chemically reacting the first and second superabsorbent polymer precursor composition to form a superabsorbent polymer;
• depositing the mixture onto the forming surface;
• and
• forming the absorbent composite nonwoven web from the mixture.

A process for making an absorbent composite nonwoven web, comprising the steps of:

• providing a first superabsorbent polymer precursor composition;
• providing at least one stream carrying a plurality of cellulose fibers;
• combining the superabsorbent polymer precursor composition with the stream carrying the cellulose fibers to form a mixture, while chemically reacting the superabsorbent polymer precursor composition to form a superabsorbent polymer;
• depositing the mixture on a forming surface;
• and
• forming the absorbent composite nonwoven web from the mixture.