Kimberly-clark Worldwide, Inc.

Victor Michael Gentile

James Jay Tanner

John Joseph Lassig

Barbara Jean Burns

Monica C Fontenot

Terry Pearce Ford

Alan Grady Shuman

Jonathan Robert Owen

Mike Thomas Goulet

Jill Anderson Georger

Denise Alice Polderman

Maurice Alan Wyatt

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

Chemical additives can be adsorbed on cellulosic papermaking fibers at high levels with a minimal amount of unadsorbed chemical additives present in the papermaking process water. A method includes treating a fiber slurry with an excess of the chemical additive, allowing sufficient residence time for adsorption to occur, filtering the slurry to remove unadsorbed chemical additives, and redispersing the filtered pulp with fresh water. Filtrate from the thickening process contains unadsorbed chemical additive and it is not sent forward in the process with the chemically treated fibers. The method can be employed to make improved paper products.

Paper products and a method for applying a dye to cellulosic fibers

An absorbent member is disclosed which has a high absorbent capacity and which exhibits exceptional expansion properties when wetted by an aqueous fluid. The absorbent member includes a multitude of randomly oriented cellulosic fibers having an average length of from between about 1 mm to about 5 mm and containing at least about 20% lignin within each fiber. The absorbent member also has a moisture content of from between about 1% to about 20% water by weight of fiber and has a density in the range of from between about 0.1 g/cc to about 1 g/cc. The fibers are stressed and bonded by hydrogen bonds and are retained in an elastically stressed condition.

Absorbent member exhibiting exceptional expansion properties when wetted

An absorbent article having exceptional expansion properties when wetted by an aqueous fluid is disclosed. The absorbent article has an absorbent member formed from a multitude of randomly oriented cellulosic fibers containing at least about 20% lignin. The absorbent member has a moisture content of from between about 1% to about 20% water by weight of fiber and the fibers are elastically stressed and bonded by hydrogen bonds. The fibers are retained in a stressed condition and have a density of from between about 0.2 g/cc to about 1 g/cc.

Absorbent article

A method for making an absorbent member is disclosed. The method includes introducing fibers into an air stream to form an air-fiber mixture. This air-fiber mixture is then directed to a porous media having a first surface. The air-fiber mixture contacts the first surface and the fibers collect on the first surface and forms a fibrous mat. The air passes through the first surface and can be recovered and recycled, if desired. The air-fiber mixture is then terminated or diverted so that the fibrous mat can be removed from the first surface. The fibrous mat is wetted by water to obtain a desired moisture content. Finally, the wetted fibrous mat is compressed to a predetermined thickness to form an absorbent member, which has unique expansion properties.

Growing community of inventors

Appleton, WI, United States of America

Victor Michael Gentile