Method and apparatus for forming a batt of particulate material for use as a component in an absorbent core assembly

Abstract

A method and apparatus for forming a batt of particulate material which may be used in an absorbent article. The apparatus may include a vacuum zone, an air impermeable fence zone adjacent to the vacuum zone, and an air permeable fence zone adjacent to the vacuum zone. The air permeable fence zone may comprise an ambient air entry conduit in communication with an ambient air exit port. The method may include providing a laydown drum and a first web of material, positioning the first web of material substantially adjacent to the laydown drum, generating a vacuum through the laydown drum, depositing particulate matter onto the first web of material, and rotating the laydown drum.

Description

FIELD OF THE INVENTION[0001]The present disclosure relates to methods and apparatuses for manufacturing disposable absorbent articles, and more particularly, methods and apparatuses for forming batts of superabsorbent polymer for use as components in absorbent core assemblies.BACKGROUND OF THE INVENTION[0002]Disposable absorbent articles, such as diapers, are often constructed with an absorbent core assembly adapted to absorb bodily exudates and positioned between layers of materials. Such absorbent core assemblies may include a mixture of fibrous and particulate materials (e.g., fluff material and superabsorbent polymer), which are formed into a batt or wad. In turn, the batt or wad may be positioned between two or more layers of materials. One such layer may be a dusting layer adapted to face the wearer's body. Another such layer may be a core wrap adapted to face away from the person's body. The batt may not extend the entire length of the diaper, and thus, is generally intended ...

AI Technical Summary

Benefits of technology

[0007]In some embodiments, the ambient air entry conduit does not extend through the surface of the laydown drum. A collective surface area of vacuum zones, air permeable fence zones, and air impermeable fence zones may equal a surface area of the outer surface of the laydown drum. The ambient air entry conduits may comprise fins at one or more laterally outermost edges of the ambient air entry conduits, whereby the fins direct ambient air into the ambient air entry conduit when the laydown drum is rotated. The vacuum zones may comprise a screen having a plurality of apertures.

[0008]The air impermeable fence zones and the air permeable fence zones may have a greater height relative to the outer surface of the support structure than the vacuum zones. The air impermeable fence zones and the air permeable fence zones may be less than about 7 mm higher than the vacuum zones relative to the outer surface of the support structure.

[0009]In some embodiments, the disclosure relates to a method of forming a batt comprising particulate material, the method comprising the steps of providing a support structure, the support structure having an outer surface and a

Problems solved by technology

However, using some current techniques and apparatuses, some superabsorbent polymer and fluff material may be inadvertently deposited outside of the vacuum zones and outside desired locations on the web.

Such deposits may cause skin irritation; may be believed to cause skin irritation; and / or may be aesthetically unacceptable to a consumer.

Additionally, fluff material inadvertently deposited substantially along the entire length of the diaper may interfere with an end seal necessary to contain the absorbent core assembly.

However, such systems add cost and complexity to the manufacturing process.

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