The US Patent and Trademark Office issued Magnera Corporation of Charlotte, NC a patent on September 1, 2026 covering a three-layer absorbent composite structure for hygiene end-uses.

The patent, filed July 18, 2018, names four co-inventors: Lei Wang, Nyle Bishop, and Pierre Grondin of Mooresville, NC, alongside Gregory Wagner Farell of Hendersonville, TN. All rights assign to Magnera.

What does the patent claim?

The construction stacks three directly bonded layers. A nonwoven top sheet of hydrophilic fibers faces the wearer.

Beneath the top sheet sits an absorbent core built from crimped multi-component continuous spunbond filaments. The core takes the form of a high-loft through-air-bonded nonwoven at a basis weight between 10 gsm and 200 gsm.

A water-impermeable film caps the system, applied by direct extrusion coating onto the through-air-bonded nonwoven or by direct adhesive bonding. The core sits between the two outer layers, joined by ultrasonic or thermal bond points rather than full-area adhesive.

How does the construction meet the claimed performance?

The patent ties the layered structure to three quantitative benchmarks governed by textile and material standards:

• Composite run-off value below 50% under ISO 9073-11
• Composite absorption capacity of at least 600% under ISO 9073
• Composite absorption rate below 10 seconds for a 5 ml liquid sample under ASTM D824-94

The high-loft substrate carries a separate mechanical specification: the web must compress by 20% or more when applied pressure rises from 0.1 kPa to 0.5 kPa, tested under BS EN ISO 9703-2 (1995).

What does this mean for converters and brand sourcing?

The patent documents manufacturing paths through ultrasonic and thermal bonding plus direct extrusion coating. Those routes sidestep adhesive-saturated laminations common in commodity absorbent cores.

Converters running through-air-bonded lines for diaper, incontinence, and feminine care applications gain a documented reference for a crimped multi-component filament core capped by direct-coated film instead of laminated barrier layers.

The 10–200 gsm basis weight window spans light topsheet-adjacent structures and heavier absorbent cores, giving the claim operational breadth across hygiene categories from ultrathin pant formats to higher-capacity overnight products.

What's the sourcing decision the patent forces?

Any absorbent hygiene converter, brand, or private-label buyer pursuing the 600% absorption capacity floor with sub-50% run-off on a through-air-bonded substrate now operates against a Magnera-controlled US patent.

Competing constructions matching the claimed run-off, capacity, and rate thresholds will require licensing, design-around engineering, or substitution of the crimped multi-component filament core layer.

The compliance decision is direct: due-diligence reviews on absorbent product lines built on through-air-bonded high-loft nonwovens with direct-coated barrier film must now include Magnera's filing, shifting IP clearance responsibility onto sourcing, R&D, and legal teams handling current and pipeline absorbent construction.