Absorbent Composites

Lei Wang, Mooresville, NC; Nyle Bishop, Mooresville, NC; Gregory Wagner Farell, Hendersonville, TN; and Pierre Grondin, Mooresville, NC.

Assigned to Magnera Corporation, Charlotte, NC.

Filed: 7/18/18
Issued: 9/1/26

An absorbent composite, comprising: (a) a nonwoven top layer comprising hydrophilic fibers; (b) an absorbent core layer consisting of a plurality of crimped multi-component continuous spunbond filaments directly bonded to the nonwoven top layer via a plurality of ultrasonic bonds or thermal bonds, wherein the absorbent core layer is a high-loft through-air-bonded nonwoven having a basis weight from 10 gsm to 200 gsm; and (c) a water impermeable film, wherein the absorbent core layer is directly sandwiched between the nonwoven top layer and the water impermeable film; wherein the water impermeable film is extrusion coated directly onto the through-air-bonded nonwoven or adhesively bonded directly onto the through-air-bonded nonwoven; wherein the absorbent composite includes (i) a composite-run-off value of less than 50% as determined by ISO 9073-11; (ii) a composite-absorption capacity of at least 600% as determined by ISO 9073; and (iii) a composite-rate of absorption of less than 10 seconds for a 5 ml liquid sample as determined by D824-94; where the high-loft through air bonded nonwoven is a material that is compressible by 20% or more when an applied pressure changes from 0.1 kPa to 0.5k Pa according to BS EN ISO 9703-2 (1995).