Adhesives and the 21st Century Absorbent Hygiene Product Core | Bostik Blog

The absorbent hygiene core has never been more complex. Improved production, cost efficiency, and consumer needs drive manufacturers to bring new core configurations to the market. Every step of the way, adhesives are there to support core integrity and performance.

The absorbent hygiene core has come a long way since the early days. CHUX marketed their ground-breaking disposable baby diaper in 1949. In 1984, Kimberly- Clark introduced adult diapers, opening up a whole new market. And as for period care … Would it surprise you to learn the first disposable pad for women, Lister Towels, hit the market way back in 1896?

As they evolved, these disposable products transformed how people live their daily lives in a multitude of ways. Now, as manufacturers explore and introduce new absorbent core designs, the future of these products seems full of possibility.

Part 1 of this series will explore new core designs, their benefits, and challenges. In Part 2, you will learn how hot melt adhesives can be used to deliver production and performance needs for today’s absorbent hygiene market.

Upgrading the Traditional Fluff/SAP Core

The Trend Toward Going Thinner

For more than 35 years, the combination of cellulose fluff with superabsorbent polymer (SAP) has remained a standard for many diapers. One long standing trend in this configuration is toward manufacturing thinner products without sacrificing performance.

These slimmer products offer benefits to both consumers and manufacturers, including:

Improved comfort
Greater discretion (especially for incontinent adults)
More compact packaging for extra efficiency in shipping and shelf space

Over the last several years, this has led to an increasing ratio of SAP to fluff. They typically range between 30% to 70% SAP. With fewer fluff fibers present, there can be issues with overall core integrity and performance. Appropriate use of hot melt adhesives is a prevalent method for addressing these concerns.

Doing More With Less: The Fluff-Free Core

Instead of reducing fluff, some manufacturers choose to remove it entirely. Benefits typically attributed to these styles include:

Sourcing efficiencies
Lower material consumption (a plus for sustainability)
Enhanced user comfort and discretion

In fluff-free cores, however, all tasks usually performed by the fluff need to be met by other means. Adhesives can assist with mitigating these issues, and Bostik core experts can help you choose the right adhesive for your particular core design.

Some article producers, however, have chosen an alternate course in pursuit of greater core integrity. This has led to the introduction of non-traditional core configurations across the globe.

Alternative Absorbent Hygiene Core Configurations

Compound and Pre-Compound Cores

Manufacturers in China created a new core design by layering SAP within absorbent top/back layers and high-loft synthetic nonwoven fabric. The primary advantages attributed to the compound/pre-compound core are:

Thinner profile
Excellent integrity when wet
Simplified production due to being fluff-free

However, a slower production speed is generally required for their creation. Because of this, they are typically formed offline and shipped to the diaper manufacturer in rolls or boxes. The term “pre-compound” is used to refer to those manufactured offline. Their inline equivalents are called “compound cores.”

There can be additional challenges, which can be mitigated through proper design and execution using absorbent hygiene hot melts.

Adhesive Helps Create Zones in the Channel Core

This design derives its name from longitudinal zones that are free of any absorbent material. A channel core is formed by bonding the upper and lower core wrap together with adhesive. The format typically also requires an adhesive to hold the SAP in place. Fluff may or may not be used.

Benefits attributed to the channel core include:
Improved core integrity and reduced risk of core cracking
Better fluid circulation for more complete core utilization
Enhanced air circulation to promote skin wellness
Less bulking and sagging

We have seen variations in design, such as in the number, shape, and positioning of channels. Some examples contain SAP plus fluff, while others contain SAP alone. In certain cases, the channels are intended to release upon insult, while others are built to remain intact.

Get the Support You Need for Absorbent Hygiene

Ask the Absorbent Hygiene Experts

For all of these core designs, adhesives play a valuable role in supporting both consumer and manufacturing needs. Learn more in Part 2: “Meeting Performance Needs in Today’s Absorbent Hygiene Core Designs.”

If you are ready to start talking about how choosing the right adhesives can support your absorbent cores and mitigate issues, let’s talk.

Contact Us

References:
Jennifer Kotler, PhD, “A Short History of Modern Menstrual Products,’ Helloclue.com

All information contained herein is believed to be accurate as of the date of publication, is provided “as-is” and is subject to change without notice. To review our full U.S. Legal Disclaimer, visit: https://bostik.com/us/en_US/privacy-policy/legal-disclaimer

Part 1: Adhesives and the 21st Century Absorbent Hygiene Product Core