Kimberly-clark Worldwide, Inc.

Jonathan Robert Owen

James Jay Tanner

John Joseph Lassig

Victor Michael Gentile

Barbara Jean Burns

Monica C Fontenot

Terry Pearce Ford

Alan Grady Shuman

The present invention pertains to an airlaid composite which is made of pulp fibers, at least about 2% by weight bicomponent fiber, and moisture. This airlaid composite is unique in that a uniformly even composite is made which upon calendering, becomes a thin structure which maintains significant absorbency when saturated. The bicomponent fibers of the present invention include a first polymer component and a second polymer component, and the first polymer component melts at a temperature lower than the melting temperature of the second polymer component. Mixing of the pulp fibers with the bicomponent fibers is done in such a way that the fibers are evenly dispersed in the airlaid composite. This airlaid composite is then heated such that at least a portion of the first polymer component of the bicomponent fiber is melted, which bond the bicomponent fibers to many of the pulp and bicomponent fibers when cooled. Moisture is added on to the composite to further facilitate bonding when the composite is subsequently subjected to calendering. Optionally, a sheet layer may be attached to the airlaid composite to form a multi-layered absorbent structure. Such composites and absorbent structures are characterized by a drape stiffness of at least about 5 cm, an absorbency of at least about 12 g/g, and a dry tensile strength of at least about 1300.

Absorbent structure including a thin, calendered airlaid composite and a process for making the composite

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Eagan, MN, United States of America

Jonathan Robert Owen