Process For Producing Absorbent Core Structures

Abstract

The present invention is method for forming a sandwich structure having a pattern of particulate material enveloped between a carrier material and a cover material. The method allows accurate forming of pre-determined pattern at high production speed. Such a method is particularly useful in the manufacture of disposable absorbent articles, such as baby diapers.

What is claimed is: 
     
         1 . An absorbent sandwich structure comprising:
 a carrier layer comprising indentations;   clusters of superabsorbent particles positioned in the indentations of the carrier material; and   a cover material bonded to the carrier material between the indentations of the carrier material and defining channel regions between neighboring clusters.   
     
     
         2 . The absorbent sandwich structure of  claim 1 , wherein the indentations are deformed out of a flat plane. 
     
     
         3 . The absorbent sandwich structure of  claim 2 , wherein:
 a first plurality of the clusters of the superabsorbent particles are arranged in a first row;   a second plurality of the clusters of the superabsorbent particles are arranged in a second row separate from the first row; and   wherein the cover material is bonded to the carrier material between the first row and the second row.   
     
     
         4 . The absorbent sandwich structure of  claim 3 , wherein the cover material is not bonded to the carrier material in channel regions between the neighboring clusters in the first row, and wherein the cover material is not bonded to the carrier material in channel regions between the neighboring clusters in the second row. 
     
     
         5 . The absorbent sandwich structure of  claim 4 , further comprising adhesive that permanently bonds the cover material to the carrier material between the first row and the second row. 
     
     
         6 . The absorbent sandwich structure of  claim 5 , wherein the first row is parallel to the second row. 
     
     
         7 . The absorbent sandwich structure of  claim 6 , wherein the first row is parallel to a characteristic axis that is angularly offset from a longitudinal axis of the absorbent sandwich structure. 
     
     
         8 . The absorbent sandwich structure of  claim 1 , wherein the clusters define circular shapes.