System and method for dry forming absorbent cores

Abstract

An apparatus and method for dry forming absorbent cores are disclosed. The apparatus has a rotatable drum having a substantially cylindrical surface. A vacuum surface having one or more holes is located substantially circumferentially around at least a portion of the substantially cylindrical surface. A vacuum chamber is located within the rotatable drum. The vacuum chamber has one or more vacuum passages forming a vacuum zone subadjacent at least a portion of the vacuum surface. A first casing sheet is supplied to overlie the vacuum surface at a first location, and a fibrous material is supplied to overlie the first casing sheet at a second location. A supply of particulate matter is deposited onto the fibrous material at a third location, and a second casing sheet is supplied to overlie the first casing sheet, fibrous material and particulate matter at a fourth location, thereby forming an absorbent core composite.

1 - 48 . (canceled)  
     
     
         49 . A method for dry forming an absorbent core composite comprising: 
 rotating a drum comprising a substantially cylindrical surface and a vacuum surface, the vacuum surface comprising one or more holes and being disposed substantially circumferentially around at least a portion of the substantially cylindrical surface;    applying a vacuum to a vacuum chamber that is disposed within the drum and that has one or more vacuum passages, thereby forming a vacuum zone subadjacent at least a portion of the vacuum surface;    applying a first casing sheet supply to overlie the vacuum surface at a first location;    applying a supply of fibrous material to overlie the first casing sheet supply at a second location;    depositing a supply of particulate matter onto the supply of fibrous material at a third location; and    applying a second casing sheet supply to overlie the first casing sheet supply, supply of fibrous material and supply of particulate matter at a fourth location, thereby forming an absorbent core composite.    
     
     
         50 . The method of  claim 49 , wherein the supply of particulate matter is a supply of superabsorbent particles.  
     
     
         51 . The method of  claim 49 , wherein the supply of fibrous material comprises a supply of cellulose acetate tow.  
     
     
         52 . The method of  claim 49 , wherein the first casing sheet supply and second casing sheet supply comprise tissue.  
     
     
         53 . The method of  claim 49 , further comprising applying the vacuum to the particulate matter to relatively homogeneously distribute the supply of particulate matter throughout the supply of fibrous material.  
     
     
         54 . The method of  claim 49 , further comprising applying the vacuum to the particulate matter to distribute the supply of particulate matter into relatively highly concentrated regions within the supply of fibrous material.  
     
     
         55 . The method of  claim 49 , further comprising pressing the second casing sheet supply against the first casing sheet supply with a lay on roll located proximal to the fourth location.  
     
     
         56 . The method of  claim 49 , wherein the third location is positioned between the second location and the fourth location.  
     
     
         57 . The method of  claim 49 , wherein the third location is not positioned between the second location and the fourth location.  
     
     
         58 . A method for dry forming an absorbent core composite comprising: 
 rotating a drum comprising a substantially cylindrical surface and a vacuum surface, the vacuum surface comprising one or more holes and being disposed substantially circumferentially around at least a portion of the substantially cylindrical surface;    applying a vacuum to a vacuum chamber that is disposed within the drum that has one or more vacuum passages, thereby forming a vacuum zone subadjacent at least a portion of the vacuum surface;    applying a first casing sheet supply to overlie the vacuum surface at a first location;    applying a supply of opened tow from a tow forming jet to overlie the first casing sheet supply at a second location;    depositing a supply of particulate matter onto the supply of opened tow at a third location using a vibratory feeder; and    applying a second casing sheet supply to overlie the first casing sheet supply, supply of opened tow and supply of particulate matter at a fourth location, thereby forming an absorbent core composite.    
     
     
         59 . An absorbent garment comprising: 
 a topsheet;    a backsheet; and    an absorbent core disposed between the topsheet and the backsheet comprising fibrous material and particulate matter;    wherein the particulate matter is distributed in the fibrous material using the apparatus of claim  1 .    
     
     
         60 . The absorbent article of  claim 59 , wherein the fibrous material comprises an opened tow of cellulose acetate and the particulate matter comprises superabsorbent particles.  
     
     
         61 . An absorbent article comprising: 
 a topsheet;    a backsheet; and    an absorbent core disposed between the topsheet and the backsheet comprising fibrous material and particulate matter;    wherein the particulate matter is distributed in the fibrous material using the method of claim  45 .    
     
     
         62 . The absorbent article of  claim 61 , wherein the fibrous material comprises an opened tow of cellulose acetate and the particulate matter comprises superabsorbent particles.