Disposable absorbent article employing an absorbent composite and method of making the same

A disposable absorbent article comprising:

• a topsheet;
• a backsheet;
• a pair of longitudinally-extending upstanding cuffs, each cuff having two sheet layers;
• a continuous absorbent composite including
• an absorbent layer of hydratable fine fibers in the form of microfibril obtained from cellulose or a derivative thereof, and absorbent polymer (SAP) particles bonded together by said hydratable fibers, and
• a nonwoven substrate supporting said absorbent layer, said absorbent layer being coated thereupon;
• and
• wherein said absorbent layer is disposed between said topsheet and said backsheet, and generally centrally at a location identified as a crotch region, said absorbent layer providing a swellable absorbent core for absorbing bodily exudates received in said crotch region;
• and
• wherein said cuffs are spaced laterally from said absorbent core, and wherein said continuous absorbent composite includes two swellable longitudinally-extending composite sections extending upwardly from said crotch region into said cuffs and between the cuff layers, said continuous absorbent composite forming an absorbent structure about said crotch region;
• and
• wherein said SAP are water-swellable bodies included in a concentration of about 20 gsm and said nonwoven substrate is a spunbond/meltblown/spunbond (SMS) having a basis weight in the range of about 10 gsm to 60 gsm;
• and
• wherein each of said swellable absorbent core and two longitudinally-extending composite sections forms a distinct swellable SAP section of said continuous absorbent composite, said continuous absorbent composite being folded between said swellable absorbent core and each said longitudinally extending composite sections to form a substantially non-swellable intersection therebetween.

In a disposable absorbent article having an absorbent core disposed between a topsheet and a backsheet, a prefabricated absorbent composite comprising:

• an absorbent layer of hydratable fine fibers in the form of microfibril obtained from cellulose or a derivative thereof, and absorbent polymer (SAP) particles bonded together by said hydratable fibers, and
• a nonwoven substrate supporting said absorbent layer, said absorbent layer being coated thereupon;
• wherein said absorbent layer is disposed between said topsheet and said backsheet, and generally centrally in said article at a location identified as a crotch region, said absorbent layer providing an absorbent core for absorbing bodily exudates received by the crotch region;
• and
• wherein said article includes a pair of longitudinally-extending, upstanding cuffs spiced laterally from said absorbent core, each cuff having two sheet layers, and wherein said absorbent composite includes two longitudinally-extending composite sections extending upwardly from the crotch region into said cuffs and between said cuff layers;
• and
• wherein said absorbent layer includes a low cross link SAP adapted to gel block upon wetting such the said backsheet is substantially impervious when wet and the backsheet is breathable when dry;
• and
• wherein each said longitudinally-extending composite sections and said absorbent core is a distinct swellable section of one continuous absorbent composite structure positioned about the crotch region, said continuous absorbent structure including folds providing an interface between each longitudinally-extending composite section and said absorbent core, each said interface being a non-SAP coated band that restricts swelling therearound.