Absorbent article formation system and method

Abstract

A system including a fluid source containing a pressurized fluid and a first valve in fluid communication with the fluid source. The first valve is configured to control a release of the pressurized fluid. The system also includes a reservoir containing a particulate material and a chute. The chute has a first chute wall defining a first opening and a second chute wall opposite the first chute wall. The second chute wall defines a second opening. The first chute wall and the second chute wall defines a first channel therebetween. The chute defines a first outlet. The first channel is in fluid communication with the reservoir and the first outlet. A first flow path extends between the first valve and the second opening such that the first flow path extends through the first opening, the first channel, and the second opening.

Description

PATENT109296-1411378-65084693PCT01ABSORBENT ARTICLE FORMATION SYSTEM AND METHODBACKGROUND

[0001] A primary function of personal care absorbent articles is to absorb and retain body exudates (e.g., urine, fecal material, blood, menses, or the like) with additional desired attributes including low leakage of the exudates from the absorbent article and a dry feel to the wearer of the absorbent article. By preventing leakage of the exudates from the absorbent article, the absorbent article intends to prevent the body exudates from soiling or contaminating a wearer's clothing or other articles, such as bedding, that can come in contact with the wearer.

[0002] Systems and methods used to make these absorbent articles include forming absorbent cores between two substrate layers. These absorbent cores typically help with liquid uptake and storage within absorbent articles. Many absorbent cores contain multiple particulate materials, such as superabsorbent material and pulp fluff or other fibrous particulate material, each of which can provide a range of properties useful in absorbing and retaining liquid bodily exudates. Some of the materials used for absorbent cores, including but not limited to superabsorbent material, can be costly. In addition, historically, portions of an absorbent core containing such materials may be cut-away or removed during manufacturing. New systems and methods optimizing the formation of absorbent articles are desired.BRIEF SUMMARY

[0003] Some aspects of the disclosure provides for a system including a fluid source containing a pressurized fluid and a first valve in fluid communication with the fluid source. The first valve is configured to control a release of the pressurized fluid. The system also includes a reservoir containing a particulate material and a chute. The chute has a first chute wall defining a first opening and a second chute wall opposite the first chute wall. The second chute wall defines a second opening. The first chute wall and the second chute wall defines a first channel therebetween. The chute defines a first outlet. The first channel is in fluid communication with the reservoir and the first outlet. A first flow path extends between the first valve and the second opening such that the first flow path extends through the first opening, the first channel, and the second opening.PATENT109296-1411378-65084693PCT01

[0004] Implementations may include one or more of the following features. The system further may include a return chute extending between the reservoir and the second opening. An interior region of the return chute may define a second flow path extending between the reservoir and the second opening. A central line of the first flow path extending through a first central point of the first opening may be offset from a second central point of the second opening. The system further may include a belt adjacent the first outlet and a basis weight sensor configured to receive data of an amount of particulate material positioned on the belt. The first valve may include a solenoid valve. The solenoid valve may include an open position and a closed position, and the closed position may be a default position of the solenoid valve. The system further may include a second valve in fluid communication with the fluid source. The chute may define a second outlet. The first chute wall and the second chute wall may define, therebetween, a second channel in fluid communication with the reservoir, the first opening, the second opening, and the second outlet. A second flow path extending between the second valve and the second opening such that the second flow path may extend through the first opening, the second channel, and the second opening. The first flow path may extend through the first channel but not the second channel and the second flow path may extend through the second channel but not the first channel. The first flow path may intersect the first channel at a point of intersection at an angle of between 60° and 120° relative to the first channel. The system further may include a non- transitory computer-readable medium encoding a set of computer-readable instructions, which, when executed on one or more processors on devices connected to a network: actuates the first valve from a closed position to an open position to release the pressurized fluid from the fluid source into the first flow path; and after sending the instructions, determines, using a sensor, if the first valve actuated from the closed position to the open position. When the non-transitory computer-readable medium determines that the first valve did not actuate from the closed position to the open position, the instructions further may include transmitting an alert indicating the first valve has failed. The instructions further may include actuating a first auxiliary valve connected to the fluid source from a closed position to an open position to release the pressurized fluid from the fluid source into the first flow path. The first valve may be configured to release the pressurized fluid at a pressure of between 0.5 bar and 8 bar. The system further may include an eductor component in fluid communication with the first valve. The first flow path may be further defined to extend from the first valve, through the eductor component, the first opening,PATENT109296-1411378-65084693PCT01 the first channel, and the second opening. The first channel may include a first channel portion oriented in a first direction transverse to a gravitational axis and a second channel portion oriented in a second direction substantially aligned with the gravitational axis. The first opening and the second opening may be between the first channel portion and the second channel portion. The first direction is transverse to the gravitational axis between 30 and 60.

[0005] Some aspects of the disclosure provides for a method of manufacturing a pulpless absorbent core including supplying particulate material from a reservoir, through a channel defined between a first chute wall and a second chute wall of a chute, the second chute wall opposite the first chute wall, to an outlet defined at an end region of the chute. The first chute wall defines a first opening and the second chute wall may define a second opening. The method also includes flowing, by actuating a valve, a pressurized fluid through the first opening, the channel, and the second opening along a first flow path. The first flow path intersects the particulate material flowing within the channel such that a first interrupted portion of the particulate material is redirected by the pressurized fluid from the channel into the second opening and a first uninterrupted portion of the particulate material within the channel exits the chute through the outlet.

[0006] Implementations may include one or more of the following features. The method further may include receiving the first interrupted portion of the particulate material in a return chute coupled to, and in fluid communication with, the second opening. The method further may include returning at least a portion of the first interrupted portion of the particulate material to a storage location. The storage location may include the reservoir. The method further may include receiving, at a computer system from a basis weight sensor, basis weight data of the first uninterrupted portion of the particulate material deposited on a substrate material and determining, using the computer system, a basis weight of the first uninterrupted portion of the particulate material deposited on the substrate material based at least in part on the basis weight data. The method further may include determining, using the computer system, a position of the first uninterrupted portion of the particulate material relative to the substrate material in a coordinate system based in part on the basis weight data and additional input data. The additional input data may include at least one of a speed of movement of the substrate material relative to the chute, light contrast between different portions of the substrate material, physicalPATENT109296-1411378-65084693PCT01 measurements determined by a computer vision system between features of the substrate material or printed markers, or additional sensor data. The method further may include determining, using the computer system, a cutting location to cut the substrate material relative to the first uninterrupted portion of the particulate material deposited onto the substrate material, and cutting the substrate material along the cutting location to form an absorbent core. The valve may include a solenoid valve. The method further may include flowing the pressurized fluid through the first opening, through a second channel defined between the first chute wall and the second chute wall, and through the second opening along a second flow path. The second flow path may intersect the particulate material flowing within the second channel such that a second interrupted portion of the particulate material flowing through the second channel is redirected by the pressurized fluid from the second channel into the second opening and a second uninterrupted portion of the particulate material within the second channel exits the chute through the outlet.

[0007] Some aspects of the disclosure provides for a system including a fluid source containing a pressurized fluid and a valve in fluid communication with the fluid source. The valve is configured to control a release of the pressurized fluid. The system also includes a reservoir containing a particulate material and a chute. The chute includes a first chute wall defining a first opening, a second chute wall opposite the first chute wall and defining a second opening, a first outlet, and an interior region defining a first flow path extending between the reservoir to the first outlet. The system also includes an eductor system coupled to the chute. The eductor system defines a second flow path in fluid communication with the valve that extends between the valve, the first opening, and the second opening. The second flow path intersects the first flow path.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] A further understanding of the nature and advantages of various embodiments may be realized by reference to the following figures. In the appended figures, similar components or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, thePATENT109296-1411378-65084693PCT01 description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

[0009] FIG. 1 depicts a schematic view of an example absorbent article formation system according to an embodiment of the disclosure.

[0010] FIG. 2A depicts a top isometric view of an example particulate material deposition system according to an embodiment of the disclosure.

[0011] FIG. 2B depicts a bottom isometric view of the particulate material deposition system of FIG. 2A according to an embodiment of the disclosure.

[0012] FIG. 3A depicts a top isometric view of an example eductor system according to an embodiment of the disclosure.

[0013] FIG. 3B depicts an exploded view of the eductor system of FIG. 3 A according to an embodiment of the disclosure.

[0014] FIG. 4A depicts a top isometric view of an example motive fluid component according to an embodiment of the disclosure.

[0015] FIG. 4B depicts a bottom isometric view of the motive fluid component of FIG. 4A according to an embodiment of the disclosure.

[0016] FIG. 5 depicts a top isometric view of an example spacer according to an embodiment of the disclosure.

[0017] FIG. 6A depicts a top isometric view of an example mixed fluid component according to an embodiment of the disclosure.

[0018] FIG. 6B depicts a bottom isometric view of the mixed fluid component of FIG. 6A according to an embodiment of the disclosure.

[0019] FIG. 7 depicts a cross-sectional view of an example eductor system according to an embodiment of the disclosure.

[0020] FIG. 8A depicts a top isometric view of an example deposition chute according to an embodiment of the disclosure.PATENT109296-1411378-65084693PCT01

[0021] FIG. 8B depicts a bottom isometric view of the deposition chute of FIG. 8A according to an embodiment of the disclosure.

[0022] FIG. 8C depicts a cross-sectional view of the deposition chute of FIG. 8 A according to an embodiment of the disclosure.

[0023] FIG. 9A depicts a cross-sectional view of an example particulate material deposition system in a first state according to an embodiment of the disclosure.

[0024] FIG. 9B depicts a cross-sectional view of the particulate material deposition system of FIG. 9A in a second state according to an embodiment of the disclosure.

[0025] FIG. 10A depicts a top view of an example absorbent article according to an embodiment of the disclosure.

[0026] FIG. 10B depicts a cross-sectional view of the absorbent article of FIG. 10A according to an embodiment of the disclosure.

[0027] FIG. 11 depicts a top view of an example absorbent article according to an embodiment of the disclosure.

[0028] FIG. 12 depicts a top view of an example absorbent article according to an embodiment of the disclosure.

[0029] FIG. 13 depicts a top view of an example absorbent article according to an embodiment of the disclosure.

[0030] FIG. 14 depicts a top view of an example absorbent article according to an embodiment of the disclosure.

[0031] FIG. 15 depicts a top view of an example absorbent article according to an embodiment of the disclosure.

[0032] FIG. 16 depicts a top view of an example absorbent article according to an embodiment of the disclosure.

[0033] FIG. 17 depicts a top view of an example absorbent article according to an embodiment of the disclosure.PATENT109296-1411378-65084693PCT01

[0034] FIG. 18 depicts a top view of an example absorbent article according to an embodiment of the disclosure.

[0035] FIG. 19 depicts a flowchart for forming an absorbent core according to an embodiment of the disclosure.

[0036] FIG. 20 depicts a flowchart for using an eductor system according to an embodiment of the disclosure.

[0037] FIG. 21 depicts a flowchart for forming an absorbent core according to an embodiment of the disclosure.

[0038] FIG. 22 depicts a block diagram of an example computer system usable with systems and methods according to embodiments of the present disclosure.DETAILED DESCRIPTION

[0039] Optimizing absorbent article design may include maximizing the exudate absorption and retention of the absorbent article while minimizing the cost involved in producing the absorbent article. This optimization can include optimizing the positioning / placement of the material of the absorbent core used in an absorbent article. For example, an absorbent core may include one or more particulate materials. The particulate materials may include absorbent materials (e.g., superabsorbent material (“SAM”), pulp fluff, and / or other fibrous absorbent material) and non-absorbent materials (e g., odor control materials, such as activated carbon particles, masking agents to further alter the aesthetic properties of the article, such as porous carbonate particles, stimulation agent particles, such as xylitol, sorbitol or urea, or the like). Each type of absorbent material can impart the absorbent cores with a range of properties useful in absorbing and retaining exudate bodily exudates. For example, pulp fluff or other fibrous particulate material may absorb exudate more quickly than SAM, while SAM may be able retain more exudate per particle than pulp fluff These greater exudate retention abilities of SAM per particle compared to using pulp fiber can lead to an absorbent article having decreased size while improving performance of the absorbent articles compared to absorbent articles that include pulp fiber. Accordingly, forming an absorbent core made comprising absorbent material that is substantially entirely SAM (e.g., greater than about 70% by weight of SAM to total absorbent material, greater than about 80% by weight of SAM to total absorbent material, greater thanPATENT109296-1411378-65084693PCT01 about 90% by weight of SAM to total absorbent material, or where the absorbent material is only SAM) can lead to greater performance of the absorbent article. However, SAM is more expensive than pulp fiber. As such, in order to efficiently produce absorbent articles with absorbent cores made entirely of SAM or with SAM in addition to other materials, while driving down costs, it is particularly important to optimize positioning / placement of the material of the absorbent core.

[0040] For example, controlling the shape of the absorbent core in an absorbent article may be useful in minimizing absorbent material usage and, therefore, minimizing material cost while also optimizing the performance of the absorbent article. For example, concentrating particulate material (e.g., SAM) in certain parts of the absorbent article can optimize the exudate absorption and retention of the absorbent article while minimizing the amount of particulate material used in the absorbent article. However, shaping absorbent cores via the application of absorbent materials in the high-speed manufacturing process for absorbent articles can be complex and can introduce manufacturing challenges. As such, it is important to optimize the production and placement of the absorbent cores in the absorbent articles.

[0041] One example conventional system of producing absorbent articles can include laying a continuous sheet of an absorbent core material (e.g. SAM) along a first substrate layer of an absorbent article and then cutting out a portion (e.g., to accommodate a curved leg region of a diaper or other absorbent article) from that continuous sheet to form an absorbent article having an absorbent core having a desired shape. However, such a method is wasteful as the portions of the absorbent core (e.g., comprising absorbent core materials such as SAM) that are cut out are unable to be recycled and are ultimately discarded. As such, shaping absorbent cores using this example conventional system can be wasteful.

[0042] In other example conventional systems, the absorbent articles can be produced by the use of blockers that block out certain portions (or an entirety) of a stream of particulate material forming the absorbent core as the particulate material is deposited on the first substrate layer. Using these blockers, the absorbent cores may be formed to have a certain shape on the first substrate layer. However, this method can lead to an uneven thickness or basis weight of the absorbent core in the finished absorbent article. In particular, the beginning and ends of eachPATENT109296-1411378-65084693PCT01 deposited portion can have a different thickness from the rest of the deposited portion as the particulate material will build up against the blocker when in a closed position. When the blocker opens up again, the buildup of particulate material will be deposited followed by a new stream of particulate material, leading to an uneven deposition. This unevenness can lead to aesthetic and performance issues with the absorbent article, in addition to limiting the ability to control the shape of the absorbent core.

[0043] The present disclosure provides an absorbent article formation system that can provide absorbent cores in an absorbent article having a desired shape and position while minimizing waste of the particulate material (e.g. SAM) and providing for high-speed manufacturing processes. In particular, the system can include an eductor system that that diverts one or more regions or portions (or an entirety) of a stream of particulate material through a high-velocity fully developed velocity profile (e.g., having a laminar fluid flow or the like). The uninterrupted portion(s) of the stream can then exit a deposition chute to form a particular shape and position on the first substrate layer positioned on a moving belt system. The diverted portions can be recycled or returned for used in the system to minimize waste. The system can form absorbent articles having optimized shapes of absorbent cores which can minimize particulate material (e.g., SAM) and reduce costs.

[0044] The term “absorbent article” refers herein to an article which may be placed against or in proximity to the body (i.e., contiguous with the body) of the wearer to absorb and contain various liquid, solid, and semi-solid exudates discharged from the body. Such absorbent articles, as described herein, are intended to be discarded after a limited period of use instead of being laundered or otherwise restored for reuse. It is to be understood that the present disclosure is applicable to various disposable absorbent articles, including, but not limited to, diapers, diaper pants, training pants, youth pants, swim pants, feminine hygiene products, including, but not limited to, menstrual pads or pants, incontinence products and other adult care garments, medical garments, surgical pads and bandages, other personal care or health care garments, and the like without departing from the scope of the present disclosure.

[0045] The term “superabsorbenf ’ refers herein to a water-swellable, water-insoluble organic or inorganic material capable, under the most favorable conditions, of absorbing at least 15 timesPATENT109296-1411378-65084693PCT01 its weight and, in an embodiment, at least 30 times its weight, in an aqueous solution containing 0.9 weight percent sodium chloride. Superabsorbent material can be natural, synthetic and modified natural polymers and materials. In addition, superabsorbent material can be inorganic materials, such as silica gels, or organic compounds, such as cross-linked polymers.

[0046] FIG. 1 depicts a schematic view of an example absorbent article formation system 100. The absorbent article formation system 100 may include unwinding and moving a first substrate layer 103 along a belt system 114 (e.g., a belt supported by one or more rollers or means of moving the belt) in a machine direction 104 (e.g., along an X-axis). In some exemplary embodiments, an adhesive applicator 105 may apply adhesive 106 to the first substrate layer 103. The adhesive applicator 105 may apply the adhesive 106 to the first substrate layer 103 pneumatically or through various coating methods — or any other suitable application method — in the form of dots, beads, swirls, or any other suitable pattern. Although, it should be noted that the adhesive applicator 105 and the adhesive 106 may be optional and not present in other embodiments.

[0047] The first substrate layer 103 may continue in the machine direction 104, arriving at a first particulate material deposition system 130a to have a first absorbent layer 120a deposited on the first substrate layer 103. The absorbent article formation system 100 may include a second particulate material deposition system 130b that deposits a second absorbent layer 120b on the first absorbent layer 120a (or an intervening layer (such as a resilient layer), where there is another component depositing materials on the first absorbent layer 120a). In other embodiments, there may be only one particulate material deposition system. The first and second particulate material deposition systems 130a, 130b may be structurally similar, however, in other embodiments, each of the particulate material deposition systems may have different components. Although only two particulate material deposition systems 130a, 130b are shown, in other embodiments, there may be more or fewer than two particulate material deposition systems (e.g., one, three, four, five, or the like) to deposit a corresponding number of absorbent layers. Although the second particulate material deposition system 130b is depicted as immediately following the first particulate material deposition system 130a in the absorbent article formation system 100, there may be other components in between the particulate materialPATENT109296-1411378-65084693PCT01 deposition systems 130a, 130b (e.g., additional rollers or the like to deposit additional layers, such as a resilient layer, as described further below, between the absorbent layers 120a, 120b).

[0048] The first particulate material deposition system 130a can include a first particulate material reservoir 113a housing particulate material (e.g., absorbent material, such as SAM or the like) and a first deposition chute 140a to direct a first stream 117a of particulate material from the first particulate material reservoir 113a toward the first substrate layer 103. The first particulate material reservoir 113a may house particulate material that is substantially all the same material, such as (by weight) about 90% or more a same material, such as about 95% or more a same material, or 100% a same material. The first particulate material reservoir 113a may house particulate material that is substantially pulp-free (e.g., pulpless) such that the first stream 117a may be a pulp-free stream of particulate material. For example, the particulate material may include (by weight) 90% or more absorbent material, such as 95% or more absorbent material, or 100% absorbent material (e.g., completely free of pulp). In some embodiments, the particulate material of the first stream 117a may be substantially entirely SAM, such as (by weight) about 90% or more SAM, such as about 95% or more SAM, or 100% SAM.

[0049] The first particulate material reservoir 113a may be a bulk solid pump or feeder configured to maintain a consistent first stream 117a through the first deposition chute 140a. The first particulate material deposition system 130a can include a first eductor system 160a to interrupt a portion (or an entirety) of the first stream 117a of SAM as the first stream 117a is passing through the first deposition chute 140a such that the first stream 117a can be selectively interrupted to provide a desired shape when the first stream 117a is applied to the first substrate layer 103, resulting in a desired shape of the first absorbent layer 120a. For clarity, the first stream 117a may be interrupted in a particular portion of the stream along the Y-axis, corresponding to SAM deposited along a width of the first substrate layer 103 (and the absorbent article). The period of time the particular portion of the first stream 117a is interrupted for determines where along the X-axis the first absorbent layer 120a is not deposited, the X-axis corresponding to the machine direction or length of the first substrate layer 103 (and the absorbent article). The first particulate material deposition system 130a can include a first return chute 115a that collects the interrupted portion(s) of particulate material to be directed back to the first particulate material reservoir 113a. In other embodiments, the first return chute canPATENT109296-1411378-65084693PCT01 collect the interrupted portions to a storage location that is not the first particulate material reservoir.

[0050] The first deposition chute 140a may be oriented relative to the first substrate layer 103 such that the first stream 117a exits the first deposition chute 140a falling substantially in a vertical direction (e.g., along a Z-axis). The particulate material may preferably be fed through the first deposition chute 140a by gravity, without any pneumatic force. However, in other embodiments, the exit region of the first deposition chute 140a may be at an angle with respect to the first substrate layer 103. For example, the exit region of the first deposition chute 140a may be at an angle of between about 45° and 90° difference with respect to the first substrate layer 103, such as between about 55° and 80°, such as between about 65° and 70°, or the like. Accordingly, in such embodiments, the first stream 117a may fall toward the first substrate layer 103 having a direction including a component in both the vertical Z-axis and the machine direction 104 (or potentially opposite the machine direction 104).

[0051] Once the first stream 117a exits the deposition chute 140a, the first stream 117a can intermix with a first adhesive 108a from a first adhesive applicator 107a and a second adhesive 110a from a second adhesive applicator 109a in a first mixing region 112a prior to depositing the particulate material onto the first substrate layer 103 to form the first absorbent layer 120a. The first adhesive applicator 107a may be positioned upstream (relative to the machine direction 104) of the deposition chute 140a while the second adhesive applicator 109a may be positioned downstream of the deposition chute 140a. In this manner, each of the adhesive applicators 107a, 109a may spray each side of the first stream 117a prior to being deposited on the first substrate layer 103a. A greater discussion of the use of the adhesive applicators 107a, 109a can be found in U.S. Pat. App. Pub. No. 2023 / 0320908, the contents of which are hereby incorporated in its entirety. Although the first particulate material deposition system 130a may include two adhesive applicators 107a, 109a, in other embodiments, the first particulate material deposition system may only include one of the first or second adhesive applicators, or additional adhesive applicators.

[0052] The second particulate material deposition system 130b can include a second particulate material reservoir 113b, a second deposition chute 140b, a second eductor systemPATENT109296-1411378-65084693PCT01160b, a second return chute 115b, a third adhesive applicator 107b, and a fourth adhesive applicator 109b performing a similar function as described above with the first particulate material deposition system 130a. For example, the second eductor system 160b may interrupt a portion or entirety of a stream particulate material flowing from the second material reservoir 113b through the second deposition chute 140b. A second stream 117b of particulate material may exit the second deposition chute 140b to be mixed with a third adhesive 108b and a fourth adhesive 110b to form a second absorbent layer 120b. The second absorbent layer 120b is deposited onto the first absorbent layer 120a (or an intervening layer). Although each of the particulate material deposition systems 130a, 130b includes corresponding pairs of adhesive applicators 107a, 107b, 109a, 109b, in other embodiments, each of the particulate material deposition systems may include more or fewer than two adhesive applicators (e.g., zero, one, three, four, or the like). In further embodiments, each of the particulate material deposition systems may not be similar and, instead, may have more or fewer components and features than the other particulate material deposition system. The second absorbent layer 120b can have a similar composition to the first absorbent layer 120a but, in other embodiments, may have a different composition (e.g., include one or more different particulate materials, including having no SAM, substantially all SAM, or the like). The second absorbent layer 120b may be deposited in a different shape than the first absorbent layer 120a based on differences in the interruption, by the second eductor system 160b, of the particulate material flowing from the second material reservoir 113b through the second deposition chute 140b.

[0053] Once the first absorbent layer 120a is deposited on the first substrate layer 103, and the second absorbent layer 120b is deposited on the first absorbent layer 120a or an intervening layer, a second substrate layer 124 may further be applied to the second absorbent layer 120b. The second substrate layer 124 may include a similar material to the first substate layer 103, however, in other embodiments, may be a different material. In some embodiments, an adhesive applicator 125 may spray an adhesive 126 onto the second substrate layer 124 prior to the second substrate layer 124 being positioned onto the second absorbent layer 120b. Although, it should be understood that the adhesive applicator 125 is optional and may not be present in some embodiments. Where present, the applied adhesive 126 may operate to more closely couple thePATENT109296-1411378-65084693PCT01 second substrate layer 124 to the second absorbent layer 120b and / or to further immobilize the particulate material within the second absorbent layer 120b.

[0054] The combination of the first substrate layer 103, the absorbent layers 120a, 120b, and the second substrate layer 124 may pass through one or more nip stations 127 to help compress the components together. In general, the nip station 127 may apply a pressure to the combination of the first substrate layer 103, the absorbent layers 120a, 120b, and the second substrate layer 124 of between about 0.5 pounds per linear inch (PLI) (88 N / m) and 1.5 PLI (263 N / m), between about 0.75 PLI (131 N / m) and 1.25 PLI (219 N / m), or the like. Such pressures help to further connect the deposited absorbent layers 120a, 120b to the substrate layers 103, 124. Although not required in all embodiments, it may be preferred for the nip station 127 to be positioned in relatively close proximity to the material deposition stations 130a, 130b such that the adhesives 108a, 108b and / or 110a, 110b are still open when the combination of the first substrate layer 103, the absorbent layers 120a, 120b, and the second substrate layer 124 passes through the nip station 127.

[0055] After the one or more nip stations 127, the combination of the first substrate layer 103, the absorbent layers 120a, 120b, and the second substrate layer 124 may pass to a cutting station 129 where the connected length of the first substrate layer 103, the absorbent layers 120a, 120b, and the second substrate layer 124 is cut into individual absorbent cores 101. The substrate layers 103, 124 may be cut into material layers and the layers between the material layers may form a composition of the absorbent core 101. As one or more of the absorbent layers 120a, 120b may be shaped such that the distribution of particulate material between the substrate layers 103, 124 are uneven, the cutting station 129 may cut the absorbent cores 101 in precise locations to ensure that each absorbent core 101 includes a particular density of particulate material (e.g., SAM or the like) that optimizes the performance of the absorbent core 101. These individual absorbent cores 101 may then be combined and / or further processed in additional manufacturing processes (not shown) for producing the absorbent articles described herein. For example, the absorbent cores 101 may be positioned between material layers to be formed as an absorbent article.

[0056] In some embodiments, the absorbent article formation system 100 may include one or more sensors to measure various characteristics of the absorbent cores 101 for use in checkingPATENT109296-1411378-65084693PCT01 the quality of the absorbent cores 101. For example, a weight sensor may measure a weight of the absorbent core 101 and a computer system may use this weight data to determine a weight profile of the absorbent cores 101 and to check whether the weight profile of the absorbent core 101 corresponds with a desired weight profile. In another example, the sensors may also include a camera that can capture images of the absorbent core 101. In a yet further example, the sensors may include a basis weight sensor that uses radio waves to determine a basis weight (e.g., the weight of a material per square area, such as grams per square meter) or density profile of particulate material of the absorbent core 101 along a length of the absorbent core 101.

[0057] In some embodiments, one or more of the sensors may be provided along any step in the production process of the absorbent core 101. For example, the sensors may be used to measure the first absorbent layer 120a after being deposited on the first substrate layer 103, and / or after the second absorbent layer 120b after being deposited on the first absorbent layer 120a or resilient layer. In one example, a weight sensor or basis weight sensor may determine a position of the absorbent layers 120a, 120b on the first substrate layer 103 or intervening layer (e.g., with a virtual coordinate system overlaid on the first substrate layer 103 or intervening layer) to determine whether the absorbent layers 120a, 120b are properly positioned (e.g., properly centered or otherwise positioned) on the first substrate layer 103 or intervening layer prior for to further processing. In this example, the computer system may additionally or alternatively determine the position of the absorbent layers 120a, 120b based on a speed of movement of the absorbent layers 120a, 120b and substrate layer 103, 124 being transported on the belt system 114. Further, the computer system may use image data collected from one or more image sensors (e.g., cameras or the like) to determine the light contrast between different portions of the substrate layer 103, 124. Even further, the computer system may use a computer vision system to determine the physical measurements between identified features or printed markers along the substrate layer 103, 124 based on image data.

[0058] If the computer system determines that the absorbent core 101 or absorbent layers 120a, 120b do not meet the threshold standards (e.g., the absorbent core 101 or absorbent layers 120a, 120b includes a particulate material weight distribution profile along the X, Y, and / or Z-axis, particulate material basis weight profile, or particulate material density profile that is undesired), the computer system may mark the absorbent core 101 or absorbent layers 120a, 120b forPATENT109296-1411378-65084693PCT01 additional processing (e.g., to discard or recycle). Additionally, the production process may be adjusted to address those inadequacies (e.g., by changing a production speed of the absorbent core 101, adjusting the pressure of the nipping station 127, adjusting a cutting location of the cutting station 129 in cutting out the absorbent core 101, adjusting one or more functions of the particulate material deposition systems 130a, 130b, as described further below, or the like). In some embodiments, an alert may be provided to an operator regarding a malfunction in the absorbent article formation system 100. For example, the computer system may determine whether the control valves of the eductor systems 160a, 160b, discussed further below, actuated (e.g., from a closed position to an open position, or vice versa) as instructed and transmit an alert if the control valves did not properly actuate. In this example, the computer system may instruct an auxiliary valve to open to compensate for the failed valve.

[0059] Components of the absorbent article formation system 100 (e.g., the particulate material deposition systems 130a, 130b) may be of metal, plastics, or other suitable materials.Additionally, these components can be manufactured through machining, milling, printing, molding, or other manufacturing processes.

[0060] The substrate layers 103, 124 may be any suitable nonwoven material. For example, the substrate layers 103, 124 may include a bonded carded web, a meltblown material, a spunbond material, including spunbond and meltblown combination webs commonly referred to SMS webs or SMMS webs or the like, a spunlace material, a hydroentangled material, an airlaid material, a coform material, or may be a material formed according to mixtures of technologies used to form the above described materials such as a spunbond-meltblown-spunbond material or other such similar materials.

[0061] The adhesives 106, 108a, 108b, 110a, 110b, 126 should have sufficient tack and cohesion to adhere surrounding components together. The adhesives 106, 108a, 108b, 110a, 110b, 126 may generally comprise hot-melt adhesives. An exemplary suitable adhesive is the TECHNOMELT DM 5402U adhesive available from Henkel Corporation. This suitable adhesive is a styrenic block copolymer based hot melt adhesive design to have high cohesion and strong specific adhesion to provide good fixation of the particulate material in the absorbent core 101 under both wet and dry conditions. It may further be generally preferable for the adhesivesPATENT109296-1411378-65084693PCT01106, 108a, 108b, 110a, 110b, 126 to be non-water soluble in order to help retain the positioning of the particulate material within the absorbent core 101 after one or more liquid insults. It has been found that rubber-based adhesives may be preferable in that they may produce absorbent cores 101 which perform superior to other adhesives, such as standard construction adhesives or olefin-based adhesives. Each of the adhesives 106, 108a, 108b, 110a, 110b, 126 may be the same, however, in other embodiments, one or more of the adhesives may be different.

[0062] As discussed above, depositing the portion(s) of particulate material (e.g., SAM or the like) from the reservoirs 113a, 113b used to form the absorbent layers 120a, 120b on the first substrate layer 103 in a certain shape and position can optimize the performance of the absorbent article while minimizing the cost of producing the absorbent article. Although various attempts have been made at optimizing such production systems, these conventional systems have a variety of drawbacks that includes wasting particulate material, suboptimal absorbent core shapes that lead to suboptimal absorbent article performance, and / or slower and inefficient production processes. These issues can be addressed by the particulate material deposition systems 130a, 130b system having the eductor systems 160a, 160b to divert a portion or entirety of the streams of particulate material flowing within the deposition chutes 140a, 140 with a fully developed velocity profile such that the particulate material can be deposited in a desired shape by controlling the deposit of particulate material along a width (defined by the Y-axis) and length (defined by the X-axis) of the absorbent core 101, as discussed further below.

[0063] FIGS. 2A and 2B depict a non-limiting example of the first particulate material deposition system 130a. As noted above, the first particulate material deposition system 130a may be structurally similar to the second particulate material deposition system 130b, however, in other embodiments each of the particulate material deposition systems may have different components. The first particulate material deposition system 130a can include a first deposition chute 140a coupled to a first eductor system 160a. For the sake of brevity, the particulate material reservoir and return chute are omitted. The first deposition chute 140a can define a chute inlet set 241, chute outlet set 242, deposition channels (e.g., the deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g, as shown in FIGS. 8A and 8B) between the chute inlet set 241 and chute outlet set 242, and a return opening 244 (e.g., defined between side walls 848, 858, as shown in FIG. 8B) that is fluidly coupled to other components. For example, a particulatePATENT109296-1411378-65084693PCT01 material reservoir (e.g., the particulate material reservoir 113a, 113b, as shown in FIG. 1) housing a particulate material (e.g., SAM, pulp fiber, or the like) can be fluidly coupled to the chute 240 such that a stream of particulate material from the particulate material reservoir can flow through the chute inlet set 241 and deposition channels, and exit through the chute outlet set 242.

[0064] The first eductor system 160a can include mixed fluid channels (e.g., the mixed fluid channel 763, as shown in FIG. 7) that are correspondingly in fluid communication with the deposition channels of the first deposition chute 140a such that the first eductor system 160a can interrupt (or divert) the flow of particulate material flowing within certain of the deposition channels. Specifically, the first eductor system 160a can generate and release a mixed fluid in certain of the mixed fluid channels to intersect with a corresponding deposition channel of the first deposition chute 140a. In this manner, the uninterrupted portion(s) of the stream can exit the chute outlet 242 and be deposited in a certain shape and position on an underlying layer, such as a first substrate layer (e.g., the first substrate layer 103), a resilient layer, or another absorbent layer (e.g., the first absorbent layer 120a). The shape of the uninterrupted portion(s) along a width of the deposited particulate material can correspond to which of the deposition channels are interrupted while a length of the gaps between the uninterrupted portion(s) may correspond to the amount of time that the stream of particulate material is interrupted.

[0065] The mixed fluids may exit the mixed fluid channels and enter the corresponding deposition channels of the chute 240 to interrupt at least a portion of the stream of particulate material flowing within those deposition channels. The mixed fluid may have a fully developed velocity profile by mixing a high-pressure fluid and ambient fluid in certain mixed fluid channels (e.g., the mixed fluid channel 763, as shown in FIG. 7) to form fluid flow that is a fully developed velocity profile. This fully developed velocity profile can minimize the vacuum pressures associated with the passing of the fluid, which can minimize the turbulence caused by the fluid’s passing on the surrounding stream of particulate matter, providing for more accurate interruption of selection portions of the particulate stream. A greater discussion of the fully developed velocity profile will be described below. The interrupted portion(s) of the particulate material may be diverted out of the return opening 244 (as shown in FIG. 2B and 8B) into a return chute in fluid communication with the deposition channels, such as the return chutes 115a,PATENT109296-1411378-65084693PCT01115b, as shown in FIG. 1. The return chute may be in fluid communication with the particulate material reservoir such that any portion(s) of the stream of particulate material diverted from the first deposition chute 140a may be returned to the particulate material reservoir for further use.

[0066] The first particulate material deposition system 130a can provide an absorbent core with a variety of shapes and positions along an underlying layer without sacrificing production efficiency or absorbent article performance, and while minimizing waste. In particular, compared to conventional systems, because the first eductor system 160a is mechanically less complex and uses a high-velocity fluid, the first eductor system 160a can shape and position the absorbent core on the first substrate layer without requiring a decrease in production speed. For example, individual absorbent cores can be formed at speeds greater than 600 products per minute (ppm), 700 ppm, 800 ppm, or the like. Additionally, as the fluid diverting the stream of particulate material in the first deposition chute 140a is a fully developed velocity profile and exits the first eductor system 160a at high velocities, portion(s) of the stream of particulate material can be thoroughly interrupted without affecting the shape and position of the uninterrupted portions of the stream of particulate material. Further, since the interrupted portion(s) of the stream of particulate material (e.g., SAM or the like) are diverted into the return chute to be returned back to the reservoir, there is minimal waste of particulate material. For at least these reasons, the first particulate material deposition system 130a provides a number of improvements upon conventional systems.

[0067] FIGS. 3A and 3B depict a non-limiting example first eductor system 160a. As shown in FIG. 3A, the first eductor system 160a may include a motive fluid component 362 and a mixed fluid component 364. As shown in FIG. 3B, spacer 380 may be positioned therebetween. As will be described further below, motive fluid (e.g., high-pressure and high-velocity air, water, or the like) may be released into valve inlets of the motive fluid component 362 to entrain ambient fluid (e.g., ambient air, water, or the like) into suction inlets of the motive fluid component 362. The motive fluid and the ambient fluid may flow through the motive fluid component 362 and the spacer 380 to intermix within the mixed fluid component 364. This mixed fluid may exit mixed fluid outlets of the mixed fluid component 364 with a fully developed velocity profile (e.g., a pressure and velocity profile that is substantially the same at any cross-section of the mixed fluid perpendicular to the mixed fluid’s flow direction) to interrupt a stream of particulate material in aPATENT109296-1411378-65084693PCT01 deposition chute 140a in the particulate material deposition system 130a (as shown in FIG. 2A). The spacer 380 may be positioned between the motive fluid component 362 and the mixed fluid component 364 to define a space between the motive fluid component 362 and the mixed fluid component 364 for the high-pressure fluid to flow into the mixed fluid component 364.

[0068] FIGS. 4A and 4B depict a non-limiting example of the motive fluid component 362. The motive fluid component 362 may define valve inlets that can be fluidly coupled to valves that can release motive fluids into the valve inlets. The motive fluid component 362 may define valve outlets for the motive fluid to flow out of and entrain (e.g., draw in through a pressure differential created by the passing of the motive fluids) ambient fluids (e.g., ambient air or the like) into the motive fluid component 362.

[0069] As shown in FIG. 4A, the motive fluid component 362 may define a first suction inlet 469a, a second suction inlet 469b, a third suction inlet 469c, a fourth suction inlet 469d, a fifth suction inlet 469e, a sixth suction inlet 469f, and a seventh suction inlet 469g at a first motive end surface 474. The suction inlets 469a, 469b, 469c, 469d, 469e, 469f, 469g may allow a first fluid to be entrained into the motive fluid component 362. Although the motive fluid component 362 is depicted as defining seven suction inlets 469a, 469b, 469c, 469d, 469e, 469f, 469g, in other embodiments, there may be more or fewer suction inlets, such as three, four, five, six, eight, nine, or the like.

[0070] The motive fluid component 362 may include a first side surface 476 and a second surface 478. The first side surface 476 may define a first valve inlet 466a, a second valve inlet 466b, a third valve inlet 466c, a fourth valve inlet 466d, a fifth valve inlet 466e, a sixth valve inlet 466f, and a seventh valve inlet 466g. The second side surface 478 may define an eighth valve inlet 468a, a ninth valve inlet 468b, a tenth valve inlet 468c, an eleventh valve inlet 468d, a twelfth valve inlet 468e, a thirteenth valve inlet 468f, and a fourteenth valve inlet 468g. Each of the side surfaces 476, 478 may define a corresponding number of valve inlets that correspond to the number of suction inlets 469a, 469b, 469c, 469d, 469e, 469f, 469g, however, in other embodiments, the number of valve inlets and suction inlets may not correspond. When the eductor system 460 is assembled in the particulate material deposition system, the valve inlets 466a, 466b, 466c, 466d, 466e, 466f, 466g, 468a, 468b, 468c, 468d, 468e, 468f, 468g may bePATENT109296-1411378-65084693PCT01 fluidly coupled to valves and a reservoir of motive fluid. In this manner, the control valves may open to release a motive fluid to flow into the valve inlets 466a, 466b, 466c, 466d, 466e, 466f, 466g, 468a, 468b, 468c, 468d, 468e, 468f, 468g. As will be described below, this motive fluid may flow through the motive fluid component 362 to create a pressure differential that entrains the ambient fluid in the suction inlets 469a, 469b, 469c, 469d, 469e, 469f, 469g into the motive fluid component 362.

[0071] The side surfaces 476, 478 may be angled relative to the first motive end surface 474. However, in other embodiments, the side surfaces may not be angled (e.g., substantially parallel) with the first motive end surface. The side surfaces 476, 478 may be mirrored about the first motive end surface 474 such that the side surfaces 476, 478 each have a substantially similar angle relative to the first motive end surface 474. However, in other embodiments, the side surfaces may each share a different angle with respect to the first motive end surface.

[0072] With reference to FIG. 4B, the motive fluid component 362 may include a third motive end surface 488 and a fourth motive end surface 489. The third motive end surface 488 may define a first valve outlet 486a, a second valve outlet 486b, a third valve outlet 486c, a fourth valve outlet 486d, a fifth valve outlet 486e, a sixth valve outlet 486f, and a seventh valve outlet 486g. The fourth motive end surface 478 may define an eighth valve outlet 487a, a ninth valve outlet 487b, a tenth valve outlet 487c, an eleventh valve outlet 487d, a twelfth valve outlet 487e, a thirteenth valve outlet 487f, and a fourteenth valve outlet 487g. The valve outlets 486a, 486b, 486c, 486d, 486e, 486f, 486g may be in fluid communication with the valve inlets 466a, 466b, 466c, 466d, 466e, 466f, 466g such that a motive fluid may flow into the valve inlets 466a, 466b, 466c, 466d, 466e, 466f, 466g and out of the valve outlets 486a, 486b, 486c, 486d, 486e, 486f, 486g. The valve outlets 487a, 487b, 487c, 487d, 487e, 487f, 487g may be in fluid communication with the valve inlets 468a, 468b, 468c, 468d, 468e, 468f, 468g such that a motive fluid may flow into the valve inlets 468a, 468b, 468c, 468d, 468e, 468f, 468g and out of the valve outlets 487a, 487b, 487c, 487d, 487e, 487f, 487g.

[0073] The motive end surfaces 488, 489 may define, therebetween, a first suction outlet 470a, a second suction outlet 470b, a third suction outlet 470c, a fourth suction outlet 470d, a fifth suction outlet 470e, a sixth suction outlet 470f, and a seventh suction outlet 470a. The suctionPATENT109296-1411378-65084693PCT01 outlets 470a, 470b, 470c, 470d, 470e, 470f, 470g may be in fluid communication with the suction inlets 469a, 469b, 469c, 469d, 469e, 469f, 469g such that ambient fluid entrained into the suction inlets 469a, 469b, 469c, 469d, 469e, 469f, 469g may flow out of the suction outlets 470a, 470b, 470c, 470d, 470e, 470f, 470g.

[0074] When assembled with other components of an eductor system, as will be described further below, the motive fluid flowing out of the valve outlets 486a, 486b, 486c, 486d, 486e, 486f, 486g, 487a, 487b, 487c, 487d, 487e, 487f, 487g may meet at the suction outlets 470a, 470b, 470c, 470d, 470e, 470f, 470g to create a pressure differential at the suction outlets 470a, 470b, 470c, 470d, 470e, 470f, 470g and entrain ambient fluid to flow into the suction inlets 469a, 469b, 469c, 469d, 469e, 469f, 469g. In particular, motive fluids may flow out of the valve outlets 486a, 487a to create a first pressure differential at the first suction outlet 470a and entrain fluids to flow into the first suction inlet 469a and out of the first suction outlet 470a, motive fluids may flow out of the valve outlets 486b, 487b to create a second pressure differential at the second suction outlet 470b and entrain fluids to flow into the second suction inlet 469b and out of the second suction outlet 470b, motive fluids may flow out of the valve outlets 486c, 487c to create a third pressure differential at the third suction outlet 470c and entrain fluids to flow into the third suction inlet 469c and out of the third suction outlet 470c, motive fluids may flow out of the valve outlets 486d, 487d to create a fourth pressure differential at the fourth suction outlet 470d and entrain fluids to flow into the fourth suction inlet 469d and out of the fourth suction outlet 470d, motive fluids may flow out of the valve outlets 486e, 487e to create a fifth pressure differential at the fifth suction outlet 470e and entrain fluids to flow into the fifth suction inlet 469e and out of the fifth suction outlet 470e, motive fluids may flow out of the valve outlets 486fa, 487f to create a sixth pressure differential at the sixth suction outlet 470f and entrain fluids to flow into the sixth suction inlet 469f and out of the sixth suction outlet 470f, and motive fluids may flow out of the valve outlets 486g, 487g to create a seventh pressure differential at the seventh suction outlet 470g and entrain fluids to flow into the seventh suction inlet 469g and out of the seventh suction outlet 470g. As will be discussed further below, the motive fluids from the valve outlets 486a, 486b, 486c, 486d, 486e, 486f, 486g, 487a, 487b, 487c, 487d, 487e, 487f, 487g and the ambient fluid from the suction outlets 470a, 470b, 470c, 470d, 470e, 470f, 470g may intermix together in another component of an eductor system.PATENT109296-1411378-65084693PCT01

[0075] The motive end surfaces 488, 489 may define an angle therebetween. As will be discussed below, this angle may be important to ensure that the motive fluids from the valve outlets 486a, 486b, 486c, 486d, 486e, 486f, 486g, 487a, 487b, 487c, 487d, 487e, 487f, 487g creates a sufficient pressure differential at the suction outlets 470a, 470b, 470c, 470d, 470e, 470f, 470g to entrain the ambient fluid into the suction inlets 469a, 469b, 469c, 469d, 469e, 469f, 469g such that the ambient fluid exits the suction outlets 470a, 470b, 470c, 470d, 470e, 470f, 470g at a desired velocity. The velocity of this exiting ambient fluid may be important to intermix with the motive fluids in another component of the eductor system (e.g., the mixed fluid component 364) to form a mixed fluid having a fully developed velocity profile.

[0076] FIG. 5 depicts a non-limiting example of the spacer 380. The spacer 380 may include a first plate 592 and a second plate 594. The plates 592, 594 (e.g., spacers) may define motive fluid channels for a motive fluid to flow in when assembled with the other components of the eductor system. In particular, the first plate 592 may define a first motive fluid channel 596a, a second motive fluid channel 596b, a third motive fluid channel 596c, a fourth motive fluid channel 596d, a fifth motive fluid channel 596e, a sixth motive fluid channel 596f, and a seventh motive fluid channel 596g. The second plate 594 may define an eighth motive fluid channel 598a, a ninth motive fluid channel 598b, a tenth motive fluid channel 598c, an eleventh motive fluid channel 598d, a twelfth motive fluid channel 598e, a thirteenth motive fluid channel 598f, and a fourteenth motive fluid channel 598g. The plates 592, 594 may be provided to couple between components of the eductor system, when assembled, such as between the motive fluid component 362 and the mixed fluid component 364, shown in FIGS. 3A and 3B. The number of motive fluid channels 596a, 596b, 596c, 596d, 596e, 596f, 596g, 598a, 598b, 598c, 598d, 598e, 598f, 598g may correspond to the number of valve and suction outlets in the motive fluid component that the spacer 380 is coupled to. However, in other embodiments, the spacer may define more or fewer motive fluid channels than valve or suction outlets of the motive fluid component. Although the spacer 380 is depicted as made of two plates 592, 594, in other embodiments, the spacer may be a monolithic structure.

[0077] FIGS. 6A and 6B depict a non-limiting example of the mixed fluid component 364. The mixed fluid component 364 may be provided to couple to other components of the eductor system (e.g., the motive fluid component 362 and the spacer 380, as shown in FIG. 3B) such thatPATENT109296-1411378-65084693PCT01 a motive fluid and ambient fluid may flow through the motive fluid component and the spacer to enter intermix within the mixed fluid component 364 and exit with a fully developed velocity profile.

[0078] With reference to FIG. 6A, the mixed fluid component 364 may include a first mixed end surface 682 and a second mixed end surface 684. The mixed end surfaces 682, 684 may be angled with respect to each other to correspond to angles of other components of the eductor system (e.g., the motive end surfaces 488, 489 of the motive fluid component 362, as shown in FIG. 4B). However, in other embodiments, the mixed end surfaces may be substantially parallel with each other. The mixed end surfaces 682, 684 may define, therebetween, a first mixed fluid inlet 672a, a second mixed fluid inlet 672b, a third mixed fluid inlet 672c, a fourth mixed fluid inlet 672d, a fifth mixed fluid inlet 672e, a sixth mixed fluid inlet 672f, and a seventh mixed fluid inlet 672g. The mixed fluid inlets 672a, 672b, 672c, 672d, 672e, 672f, 672g may be sized and shaped to receive motive fluid and ambient fluid so that those fluids can mix within the mixed fluid component 364 sufficiently to form a mixed fluid that exits the mixed fluid component 364 with a fully developed velocity profile.

[0079] With reference to FIG. 6B, the mixed fluid component 364 may include a third mixed end surface 675. The third mixed end surface 675 may be curved to correspond to a deposition chute, such as the deposition chute 242 shown in FIGS. 2A and 2B. However, in other embodiments, the third mixed end surface 675 may have other surface geometries, such as planar, angular, or the like. The third mixed end surface 675 may define a first mixed fluid outlet 667a, a second mixed fluid outlet 667b, a third mixed fluid outlet 667c, a fourth mixed fluid outlet 667d, a fifth mixed fluid outlet 667e, a sixth mixed fluid outlet 667f, and a seventh mixed fluid outlet 667g. The mixed fluid outlets 667a, 667b, 667c, 667d, 667e, 667f, 667g may be sized and shaped such that the mixed fluid exiting the mixed fluid outlets 667a, 667b, 667c, 667d, 667 e, 667f, 667g may exit with a fully developed velocity profile.

[0080] FIG. 7 depicts a cross-sectional view of the first eductor system 160a. The cross- sectional view of the first eductor system 160a may be similar to a cross-sectional view along Section B-B of the first eductor system 160a as shown in FIG. 3 A, which cross-sects the leftmost valve and outlets, suction inlets and outlets, motive deposition channels, and mixed fluidPATENT109296-1411378-65084693PCT01 inlets and outlets of the first eductor system 160a. In other words, Section B-B cross-sects: the first suction inlet 469a, the first valve inlet 466a, the eighth valve inlet 468a, the first valve outlet 486a, the eighth valve outlet 487a, and the first suction outlet 470a, as shown in FIGS 4A and 4B; the first motive fluid channel 596a and the eighth motive fluid channel 598a, as shown in FIG. 5; and the first mixed fluid inlet 672a and the first mixed fluid outlet 667a, as shown in FIGS. 6A and 6B. Although the following description describes the above-noted features of an eductor system, the description of the first eductor system 160a may also apply to other portions of the first eductor system 160a that corresponds to the other channels, inlets, and outlets shown in FIGS. 4A-6B.

[0081] The first eductor system 160a may include a first control valve 791 and a second control valve 793, each of which are schematically represented in FIG. 7, coupled (e.g., through fasteners, adhesive, welding, brazing, or the like) to the motive fluid component 362. Although not shown, each of the first control valve 791 and the second control valve 793 may be coupled to a reservoir of motive fluid (e.g., a motive fluid source containing pressurized or compressed fluid, such as air or the like). In other words, the valves 791, 793 can share a similar reservoir of motive fluid. However, in other embodiments, each of the valves can be fluidly coupled to their own corresponding reservoir of motive fluid. The first control valve 791 may couple to the first side surface 476 such that the first control valve 791 releases a first motive fluid into the first valve inlet 466a. The second control valve 793 may couple to the second side surface 478 such that the second control valve 793 releases a second motive fluid into the eighth valve inlet 468a. Although only one valve 791, 793 is depicted as being fluidly coupled to the corresponding valve inlet 466a, 468a, in other embodiments, there may be more than one valve fluidly coupled to each valve inlet, such as auxiliary valves for use when the primary valves (e.g., the valves depicted in FIG. 7) fails. In yet other embodiments, there may be only one control valve connected to both the first side surface and the second side surface such that one control valve can control the release of motive fluid into both the motive fluid channels. Accordingly, it should be understood that a singular control value would be sufficient to could control the flow of the first and second motive fluids to the motive fluid component, even where multiple control valves are coupled to the motive fluid component.PATENT109296-1411378-65084693PCT01

[0082] The control valves 791, 793 may be a fast-acting valve that is capable of consistently opening and closing the flow of the second fluid from the reservoirs fluidly coupled to the control valves 791, 793 at a high rate. For example, the control valves 791, 793 may be a solenoid valve, a coaxial valve, an angle seat valve, or the like. The control valves 791, 793 may each be the same type of valve, however, in other embodiments, each of the control valves are different. Where the control valves 791, 793 include a solenoid valve, the control valves 791, 793 can be a 2 / 2-way valve having two ports and two positions, a 3 / 2-way valve having three ports and two positions, a 5 / 2-way valve having five ports and two positions, or the like. The solenoid valve may be actuatable between an open position to release the motive fluid into the valve inlets 466a, 468a and a closed position to close the valve inlets 466a, 468a from the reservoir of motive fluid. In some embodiments, it may be desirable for the control valves 791, 793 to be in a closed position by default. In this manner, a loss of power to the first eductor system 160a prevents flow of the first and / or second fluid from the reservoirs through the valve inlets 466a, 468a. However, in other embodiments, the control valves may be in an open position by default.

[0083] The control valves 791, 793 may be operable to open and close at sufficiently high speeds to allow for a desired production speed. For example, the control valves 791, 793 may be operable to transition from a first position (e.g., a closed position or the like) to a second position (e.g., an open position or the like), and transition back to the first position at a speed of between 1 ms and 20 ms, such as between about 2 ms and 15 ms, such as between about 3 ms and 10 ms, such as between about 4 ms and 5 ms, or the like. These transition speeds are important to produce a desired shape and speed of the fluid pulse exiting the first mixed fluid outlet 667a, which, in turn, is important for appropriately diverting the interrupted portion of the stream of particulate material without detrimentally impacting the remaining portion of the stream of particulate material. In some embodiments, the control valves 791, 793 may transition from the closed position to the open position within a first time period and may transition from the open position to the closed position within a second time period greater than the first time period (e.g., holding the open position for longer to let a longer stream of motive fluid out). However, in other embodiments, the first and second time period may be substantially similar, the first time period may be greater than the second time period, or the vice versa. In this manner, the first eductorPATENT109296-1411378-65084693PCT01 system 160a may generate a mixed fluid and interrupt a stream of particulate material at sufficiently high speeds that production speeds of the absorbent core can be consistently maintained at speeds greater than 600 ppm, 700 ppm, 800 ppm, or the like. Additionally, the control valves 791, 793 can be kept open for a period of time to provide a longer stream of motive fluid which, as will be discussed below, can increase a length of the gap between uninterrupted portions of particulate material. The motive fluid may flow from the control valves 791, 793 at a sufficiently high pressure and speed to create a pressure differential when the motive fluid enters the mixed fluid component 364. For example, the motive fluid may flow from the control valves 791, 793 at a release pressure of between about 0.01 bar and 10 bar, such as between about 0.5 bar and 8 bar, such as between about 1 bar and 6 bar, such as between about 1.5 bar and 4 bar, such as between about 2 bar and 3 bar, or the like.

[0084] The motive fluid component 362 may define a first valve channel 781 extending between the first valve inlet 466a and the first valve outlet 486a. The motive fluid component 362 may also define a second valve channel 783 extending between the eighth valve inlet 468a and the eighth valve outlet 487a. The first motive fluid may flow from the first control valve 791, through the first valve inlet 466a, the first valve channel 781, and the first motive fluid channel 596a, to exit the motive fluid component 362 from the first valve outlet 486a. The second motive fluid may flow from the second control valve 793, through the eighth valve inlet 468a, the second valve channel 783, and the second motive fluid channel 598a to exit the motive fluid component 362 from the eighth valve outlet 487a. The first and second motive fluid may be released within the motive fluid channels 596a, 598a at a pressure less than the stored pressure of fluid in the fluid source. For example, the motive fluids may have a release pressure in the motive fluid channels 596a, 598a of between about 25% and 90% of the stored pressure in the fluid source, such as between about 30% and 85%, such as between about 35% and 80%, such as between about 40% and 75%, such as between about 45% and 70%, such as between about 50% and 65%, or about 60%.

[0085] The motive fluid component 362 may define a suction channel 761 between the first suction inlet 469a and the first suction outlet 470a. Ambient fluid may be entrained into the suction channel 761 by the motive fluids from the control valves 791, 793 entering the mixed fluid component 364. The suction channel 761 may have certain dimensions and shapes to allowPATENT109296-1411378-65084693PCT01 for ambient fluid to be entrained into the suction channel 761 with sufficient speed such that, when the ambient fluid is mixed with motive fluid in the mixed fluid component 364, the mixed fluid may exit the mixed fluid component 364 with a fully developed velocity profile.

[0086] In another example, the suction channel 761 may include a first suction portion 765 adjacent the first suction inlet 469a and a second suction portion 779 extending from the first suction portion 765 to the first suction outlet 470a. The first suction portion 765 may be geometrically shaped to draw in a sufficient amount of ambient fluid for use in generating an air mass with a fully developed velocity profile. In some embodiments, the first suction portion 765 may have a substantially funnel cross-sectional shape as defined between a first channel wall 771 and a second channel wall 785. The channel walls 771, 785 may be curved to have a radius of between about 4 cm and 8 cm, such as between about 5 cm and 7 cm, or such as about 6 cm. However, in other embodiments, the first suction portion may not be curved. In this example, the suction channel may have a substantially similar width along a length of the suction channel. In yet other embodiments, the first suction portion may have other shapes, such as being step-wise, angular, or the like. Additionally, the first suction inlet 469a may have a first width dl of between about 14 mm and 22 mm, such as between about 16 mm and 20 mm, such as about 18 mm. The shape and dimensions of the first suction inlet 469a and the first suction portion 765 can optimally draw in a sufficient amount of air to generate a fully developed velocity profile, as will be described further below.

[0087] The second suction portion 779 may have dimensions to allow for the first fluid drawn in from the first suction inlet 469a to flow toward the first suction outlet 470a for use in generating a fully developed velocity profile. For example, the second suction portion 779 (including the first suction outlet 470a) may have a second width d2 may be between about 1 mm and 15 mm, such as between about 2 mm and 10 mm, such as between about 3 mm and 5 mm, or about 4 mm. In this manner, in some embodiments, the suction outlet 470a and / or the second suction portion 779 may have a lesser cross-sectional area than the first suction inlet 469a. The second width d2 can optimally allow the first fluid to flow from the first suction inlet 469a toward the first suction outlet 470a.PATENT109296-1411378-65084693PCT01

[0088] The motive fluid component 362 and the mixed fluid component 364 may include the first plate 592 and the second plate 594 coupled therebetween (e g., through fasteners, adhesive, welding, brazing, or the like). The motive fluid component 362, the mixed fluid component 364, and the first plate 592 may define the first motive fluid channel 596a therebetween. The motive fluid component 362, the mixed fluid component 364, and the second plate 594 may define the eighth motive fluid channel 598a therebetween. Each of the motive fluid channels 596a, 598a may be corresponding fluidly coupled to the valve outlets 486a, 487a such that the motive fluids from the control valves 791, 793 through the valve channels 781, 783 and valve outlets 486a, 487a, and into the motive fluid channels 596a, 598a. The motive fluid channels 596a, 598a may extend from the valve outlets 486a, 487a to the first suction outlet 470a and the first mixed fluid inlet 672a. In this manner, the control valves 791, 793 may be opened to release the motive fluids to flow from the reservoirs through the motive fluid channels 596a, 598a and into the first mixed fluid inlet 672a.

[0089] The motive fluid channels 596a, 598a may have dimensions and orientations that allow the flow of the motive fluid to optimally draw in the ambient fluid to later form a fully developed velocity profile. Each of the motive fluid channels 596a, 598a may have similar dimensions and orientations. For the sake of brevity, the following discussion will be directed to the first motive fluid channel 596a however, it is understood that the eighth motive fluid channel 598a may also share similar dimensions. The first motive fluid channel 596a may have a width d3 corresponding to a thickness of the plates 592, 593. For example, the width d3 may be between about 0.25 mm and 1.2 mm, such as between about 0.4 mm and 1.0 mm, such as between 0.55 mm and 1.0 mm, or about 0.7 mm. The first motive fluid channel 596a may have a length from the first valve outlet 486a to the first suction outlet 470a of between about 1 mm and 20 mm, such as between about 2 mm and 15 mm, such as between about 4 mm and 13 mm, such as between about 6 mm and 13 mm, such as between about 8 mm and 11 mm, or about 10 mm. The first motive fluid channel 596a may be oriented relative to the suction channel 361 at an angle al of between about 10° and 90°, between about 20° and 60°, between about 30° and 50°, or about 40°. This orientation and dimension may allow for the motive fluid to flow through the first motive fluid channel 596a to optimally draw in, and mix with, the ambient fluid to later form aPATENT109296-1411378-65084693PCT01 fully developed velocity profile. In other embodiments, each of the motive fluid channels may have different dimensions from each other.

[0090] A pressure differential is created by the motive fluids from the motive fluid channels 596a, 598a passing the first suction outlet 470a and entering the first mixed fluid inlet 672a. This pressure differential entrains the ambient fluid outside of the first eductor system 160a to flow into the first suction inlet 469a, through the suction channel 761, and out of the first suction outlet 470a. In some embodiments, a portion of the motive fluid may enter the suction channel 761. This portion may have minimal effect on the entrainment of the ambient fluid into the suction channel 761. However, in other embodiments, substantially all (e.g., greater than 90% of the motive fluid, greater than about 95%, greater than 98%, or 100%) may enter the first mixed fluid inlet. The motive fluid from the motive fluid channels 596a, 598a and the ambient fluid from the suction channel 761 may then enter the first mixed fluid inlet 672a to be mixed in the mixed fluid component 364. The mixed fluid component 364 may define a mixed fluid channel 763 that extends from the first mixed fluid inlet 672a to the first mixed fluid outlet 667a. The motive fluids and the ambient fluid from the motive fluid component 362 may mix within the mixed fluid channel 763 such that the mixed fluid exits the first mixed fluid outlet 667a with a fully developed velocity profile. As noted above, this fully developed velocity profile of the mixed fluid exiting the mixed fluid outlet 667a is beneficial to thoroughly divert portion(s) of a stream of particulate material (e.g., SAM or the like) without leaving behind a vacuum that affects the shape and position of the uninterrupted portion(s) of the stream.

[0091] The mixed fluid channel 763 can have dimensions from the suction outlet 470a to the first mixed fluid outlet 667a to allow for the mixed fluid to mix and stabilize to a fully developed velocity profile upon exiting the first mixed fluid outlet 667a. For example, the mixed fluid channel 763 can have a width similar to the first width dl of the second suction portion 779. However, in other embodiments, the mixed fluid channel may have a different width from the suction channel. The mixed fluid channel 763 can have a length of between about 20 mm and 60 mm, between about 30 mm and 40 mm, or about 40 mm. These dimensions may allow for the lower speed of the ambient fluid and the higher speed of the motive fluid to have sufficient time and space in the mixed fluid channel 763 to mix together to form a fully developed velocity profile once the mixed fluid reaches the first mixed fluid outlet 667a.PATENT109296-1411378-65084693PCT01

[0092] As noted above, although the above discussion regarding mixing the ambient and motive fluids in the mixed fluid channel 763 was directed to the first suction inlet 469a and first mixed fluid outlet 667a, a similar process may be applied for the other suction inlets 469b, 469c, 469d, 469e, 469f, 469g and mixed fluid outlets 667b, 667c, 667d, 667e, 667f, 667g. The release of mixed fluid may be controlled for particular mixed fluid outlets 667a, 667b, 667c, 667d, 667e, 667f, 667g by actuating the control valves (e.g., the control valves 791, 793) correspondingly coupled to (e.g., correspondingly in fluid communication with) to those mixed fluid outlets 667a, 667b, 667c, 667d, 667e, 667f, 667g is actuated. In turn, as only certain of the deposition channels are interrupted, an absorbent layer having a particular gap pattern along a width-wise axis may be deposited. Additionally, holding the release of mixed fluid from certain of the mixed fluid outlets 667a, 667b, 667c, 667d, 667e, 667f, 667g for a different period of time may result in certain of the gaps having a different length and / or have differing relative positions within the remaining portion of the stream of particulate material. In this manner, the first eductor system 160a may provide the mixed fluid to interrupt stream of particulate material to provide an absorbent layer having a desired pattern.

[0093] FIGS. 8A-8C depict a non-limiting example of the first deposition chute 140a. The first deposition chute 140a may include channel walls that define deposition channels therebetween. In particular, the first deposition chute 140a may include a first channel wall 847a, a second channel wall 847b, a third channel wall 847c, a fourth channel wall 847d, a fifth channel wall 847e, a sixth channel wall 847f, a seventh channel wall 847g, and an eighth channel wall 847h. Each of the channel walls 847a, 847b, 847c, 847d, 847e, 847f, 847g, 847h may extend from a first end 850 of the first deposition chute 140a to a second end 851 of the first deposition chute 140a. Although eight channel walls 847a, 847b, 847c, 847d, 847e, 847f, 847g, 847h are depicted, in other embodiments, there may be any number of channel walls, such as two, three, four, or the like. The channel walls 847a, 847b, 847c, 847d, 847e, 847f, 847g, 847h may be structurally similar, however, in other embodiments, one or more of the channel walls may be different from each other, such as having different shapes, dimensions, or the like.

[0094] The channel walls 847a, 847b, 847c, 847d, 847e, 847f, 847g, 847h may define deposition channels therebetween. In particular, the channel walls 847a, 847b may define, therebetween, a first deposition channel 845a, the channel walls 847b, 847c may define,PATENT109296-1411378-65084693PCT01 therebetween, a second deposition channel 845b, the channel walls 847c, 847d may define, therebetween, a third deposition channel 845c, the channel walls 847d, 847e may define, therebetween, a fourth deposition channel 845d, the channel walls 847e, 847f may define, therebetween, a fifth deposition channel 845e, the channel walls 847f, 847g may define, therebetween, a sixth deposition channel 845f, and the channel walls 847g, 847h may define, therebetween, a seventh deposition channel 845g. Each of the deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g can be geometrically similar, however, in other embodiments, one or more of the deposition channels can be structurally different, such as having a different shape and / or different dimension. Although FIG. 8A depicts seven deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g, in other embodiments, there may be more or fewer than seven deposition channels, such as three, or four, or eight, or nine, or any suitable number.

[0095] The first end 850 may couple to a particulate material reservoir (e.g., the particulate material reservoirs 113a, 113b, as shown in FIG. 1). As noted above, the first deposition chute 140a may define a chute inlet set 241 and a chute outlet set 242. Specifically, as shown in FIG. 8B, the first end 850 may define the chute inlet set 241 to include a first chute inlet 841a, second chute inlet 841b, a third chute inlet 841c, a fourth chute inlet 841d, a fifth chute inlet 841e, a sixth chute inlet 841f, and a seventh chute inlet 841g. The second end 851 may be directed toward a forming surface, such as a belt system (e.g., the belt system 114, as shown in FIG. 1). The second end 851 may define the chute outlet set 242 to include a first chute outlet 842a, second chute outlet 842b, a third chute outlet 842c, a fourth chute outlet 842d, a fifth chute outlet 842e, a sixth chute outlet 842f, and a seventh chute outlet 842g. The number of chute inlets 841a, 841b, 841c, 841d, 841e, 841f, 841g and chute outlets 842a, 842b, 842c, 842d, 842e, 842f, 842g may correspond to the number of deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g.

[0096] The deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g may be in fluid communication with the chute inlets 841a, 841b, 841c, 84 Id, 84 le, 84 If, 841g and the chute outlets 842a, 842b, 842c, 842d, 842e, 842f, 842g such that, when the first deposition chute 140a is coupled in a particulate material deposition system, particulate material may flow from the chute inlets 841a, 841b, 841c, 841d, 841e, 841f, 841g, through one or more of the deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g, and out the chute outlet 842a, 842b, 842c, 842d, 842e, 842f, 842g. As such, a stream of particulate material may flow through thePATENT109296-1411378-65084693PCT01 deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g from the first end 850 downstream to the second end 851. “Upstream” as used with regard to the first deposition chute 140a may describe a point in the deposition channel 845a, 845b, 845c, 845d, 845e, 845f, 845g closer to the first end 850 and “downstream” may describe a point closer to the second end 851.

[0097] The first deposition chute 140a may include a first side wall 846, a second side wall 848 opposite the first side wall 846, a third side wall 856, and a fourth side wall 858 opposite the third side wall 856. The side walls 846, 856 may, collectively, define a first chute wall. The side walls 848, 858 may, collectively, define a second chute wall that is opposite the first chute wall. The first side wall 846 and the second side wall 848 may partially define a downstream portion of the deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g. The third side wall 856 and the fourth side wall 858 may partially define an upstream portion of the deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g.

[0098] The first side wall 846 and the third side wall 856 (e.g., the first chute wall collectively defined by the side walls 846, 856) may define, therebetween, an eductor opening 843. The eductor opening 843 may be sized and shaped such that another component of the particulate material deposition system (e.g., a mixed fluid component 364 of a first eductor system 160a, as shown in FIGS. 3 A and 3B) may couple to the first deposition chute 140a. The first side wall 846, the third side wall 856, and channel walls 847a, 847b, 847c, 847d, 847e, 847f, 847g, 847h may also define interruption windows for receiving a fluid from an eductor system (e.g., the first eductor system 160a, as shown in FIGS. 3 A and 3B) into each corresponding deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g. For example, the side walls 846, 856 and the channel walls 847a, 847b may define a first interruption window 857a, the side walls 846, 856 and the channel walls 847b, 847c may define a second interruption window 857b, the side walls 846, 856 and the channel walls 847c, 847d may define a third interruption window 857c, the side walls 846, 856 and the channel walls 847d, 847e may define a fourth interruption window 857d, the side walls 846, 856 and the channel walls 847e, 847f may define a fifth interruption window 857e, the side walls 846, 856 and the channel walls 847f, 847g may define a sixth interruption window 857f, and the side walls 846, 856 and the channel walls 847g, 847h may define a seventh interruption window 857g. The interruption windows 857a, 857b, 857c, 857d, 857e, 857f, 857g may form a portion of the eductor opening 843. In some embodiments, thePATENT109296-1411378-65084693PCT01 interruption windows 857a, 857b, 857c, 857d, 857e, 857f, 857g may, collectively, form the eductor opening 843. As noted above, a fluid may enter certain of the deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g from a corresponding interruption window 857a, 857b, 857c, 857d, 857e, 857f, 857g to interrupt one or more streams of particulate material flowing within the deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g. In particular, interrupting the flow of particulate material within certain of the deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g may result in the absorbent layer having a certain gap pattern along a widthwise axis while interrupting the flow of particulate material within those deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g for a different amount of time may result in those gaps having different lengths along a length-wise axis.

[0099] The second side wall 848 and the fourth side wall 858 (e.g., the second chute wall collectively defined by the side walls 848, 858) may define, therebetween, a return opening 244. The return opening 244 may be sized and shaped such that another component of the particulate material deposition system (e.g., e.g., the return chute 115a, 115b, as shown in FIG. 1) may couple to the first deposition chute 140a. The second side wall 848, the fourth side wall 858, and channel walls 847a, 847b, 847c, 847d, 847e, 847f, 847g, 847h may also define bypass windows for receiving an interrupted portion of a stream of particulate material from each corresponding deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g into a return chute (e.g., the return chute 115a, as shown in FIGS. 9A and 9B). For example, the side walls 848, 858 and the channel walls 847a, 847b may define a first bypass window 844a, the side walls 848, 858 and the channel walls 847b, 847c may define a second bypass window 844b, the side walls 848, 858 and the channel walls 847c, 847d may define a third bypass window 844c, the side walls 848, 858 and the channel walls 847d, 847e may define a fourth bypass window 844d, the side walls 848, 858 and the channel walls 847e, 847f may define a fifth bypass window 844e, the side walls 848, 858 and the channel walls 847f, 847g may define a sixth bypass window 844f, and the side walls 848, 858 and the channel walls 847g, 847h may define a seventh bypass window 844g. Particulate material that is interrupted from the stream of particulate material flowing in the deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g may be received through the corresponding bypass window 844a, 844b, 844c, 844d, 844e, 844f, 844g.PATENT109296-1411378-65084693PCT01

[0100] FIG. 8C depicts a cross-sectional view of the first deposition chute 140a along Section C-C, as noted in FIG. 8 A, across the first chute inlet 841a, the first chute outlet 842a, and the first deposition channel 845a. However, it is understood that the other chute inlets 841b, 841c, 84 Id, 84 le, 84 If, 841g, chute outlets 842b, 842c, 842d, 842e, 842f, 842g, and deposition channels 845b, 845c, 845d, 845e, 845f, 845g may share similar features to the first chute inlet 841a, the first chute outlet 842a, and the first deposition channel 845a.

[0101] It may be beneficial for the side walls 846, 848, 856, 858 and the channel walls 847a, 847b to define the first interruption window 857a and the first bypass window 844a (and, therefore a position of other components coupled to the first interruption window 857a and the first bypass window 844a, such as the first eductor 160a and first return chute 115a, as seen in FIGS. 9A and 9B) at a position prior to the stream of particulate material entering free fall (e.g., where the stream of particulate material is substantially free of other forces except gravity) as the fourth side wall 858 may be angled relative to a vertical Z-axis such that a stream of particulate material (e.g., SAM or the like) may flow along the fourth side wall 858 to be carried by momentum over the first bypass window 844a without falling into the first bypass window 844a. For example, the first deposition channel 845a may include a first channel portion 854 upstream of the first bypass window 844a, a second channel portion 855 downstream of the first bypass window 844a, and a third channel portion 853 positioned between the channel portions 854, 855. The first channel portion 854 may be defined between the third side wall 856 and the fourth side wall 858. The second channel portion 855 may be defined between the first side wall 846 and the second side wall 848. The third channel portion 853 may not be defined by any of the side walls 846, 848, 856, 858 and, instead, may be defined only between channel walls 847a, 847b. When assembled with a particulate material deposition system, the third channel portion 853 may be further defined between other components, such as a return chute and an eductor system.

[0102] In use, the stream of particulate material in the first channel portion 854 may flow along, and be at least partially supported by, the fourth side wall 858 along the Z-axis. As the stream of particulate material flows past the first channel portion 854, the stream of particulate material may transition from being supported the fourth side wall 858 to beginning to enter freefall (e.g., not being supported in a Z-axis by the fourth side wall 858) in the third channel portion 853. Once the stream of particulate material flows past the third channel portion 853, thePATENT109296-1411378-65084693PCT01 stream of particulate material may flow in the second channel portion 855 in free fall. The first channel portion 854 may define a first direction extending from the first chute inlet 841a that is transverse to a gravitational direction (e.g., the Z-axis) by an angle between about 20° and 70°, such as between about 30° and 60°, such as between about 40° and 50°, or about 45°.

[0103] As noted above, the stream of particulate material (e.g., SAM or the like) flowing in the first deposition channel 845a may be interrupted by a fluid coming from the first interruption window 857a. As such, defining the first interruption window 857a along the first deposition chute 140a at the third channel portion 853, where the stream of particulate material begins to enter free fall, may be beneficial because the shape of the first deposition channel 845a may allow the particulate material to flow past first interruption window 857a while minimizing particulate material entering first interruption window 857a as the momentum of the stream of particulate material may carry the stream past the first interruption window 857a along a parabolic path. However, in other embodiments, the entire deposition channel may be oriented along the Z-axis such that stream of particulate material may be in free fall along the entire length of the deposition channel. In yet other embodiments, none of the deposition channel may be oriented to be completely along the Z-axis such that the stream of particulate material will be at least partially supported along the Z-axis by at least one side wall.

[0104] A first central point of the first interruption window 857a may be offset from a second central point of the first bypass window 844a along a direction perpendicular to the first deposition channel 845a (e.g., offset in a flow direction from the first interruption window 857a into the third channel portion 853). This offset may be beneficial to allow the first bypass window 844a to better receive an interrupted portion of particulate material when the first deposition chute 140a is assembled with an eductor system. In particular, as will be described further below, an air mass may enter the first deposition channel 845a from the first interruption window 857a to interrupt a portion of a stream of particulate material flowing within the deposition channel 845a. As this interrupted portion of particulate material will continue falling in a Z-axis due to gravity, positioning the first central point of the first interruption window 857a eccentric from the second central point of the first bypass window 844a can account for the decrease in height from where the portion of particulate material was interrupted in the first deposition channel 845a to the first bypass window 844a. However, in other embodiments, thePATENT109296-1411378-65084693PCT01 first return opening and the first eductor opening may be concentric with each other (e.g. the central points of the first return opening and the first eductor opening may be concentric with each other). Although the first bypass window 844a is depicted offset downstream from the first interruption window 857a, in other embodiments, the return opening may be offset upstream from the eductor opening. In a yet further embodiment, the return opening and the eductor opening may be aligned with each other (e.g., concentric along a flow direction from the eductor opening into the third channel portion).

[0105] An example flow of particulate material (e.g., SAM or the like) using the particulate material deposition system will now be described with reference to FIGS. 9A and 9B. In particular, FIGS. 9A and 9B depict the first particulate material deposition system 130a in use. The first particulate material reservoir 113a and the first return chute 115a are depicted schematically. Although the method will be described with reference to the first deposition channel 845a, suction channel 761, valve channels 781, 783, motive fluid channels 596a, 598a, and mixed fluid channel 763, it is understood that a similar method may be used for each of the other deposition channels (e.g., deposition channels 845b, 845c, 845d, 845e, 845f, 845g, as shown in FIGS. 8A and 8B) in the first deposition chute 140a, the other suction channels, valve channels and motive fluid channels (e.g., the motive fluid channels 596b, 596c, 596d, 596e, 596f, 596g, 598b, 598c, 598d, 598e, 598f, 598g, as shown in FIG. 5) in the motive fluid component 362, and the other mixed fluid channels in the mixed fluid component 364.

[0106] FIG. 9A depicts the first particulate material deposition system 130a in a first state, where an uninterrupted particulate stream 919 flows within the first deposition channel 845a. Specifically, the uninterrupted particulate stream 919 may flow along a deposition flow path A from the first particulate material reservoir 113a, through the first chute inlet 841a and the first deposition channel 845a, to exit the first chute outlet 842a (e g., onto a substrate layer or other layer on a belt system, such as the belt system 114, as shown in FIG. 1). The uninterrupted particulate stream 919 may flow past the first eductor system 160a and the first return chute 115a without being interrupted such that the particulate stream 919 is a contiguous flow from the first particulate material reservoir 113a to the first chute outlet 842a.PATENT109296-1411378-65084693PCT01

[0107] The uninterrupted particulate stream 919 may flow from the first particulate material reservoir 113a with an average basis weight of particulate material between 100 gsm and 500 gsm, such as between 150 gsm and 450 gsm, such as between about 200 gsm and 400 gsm, such as between about 250 gsm and 350 gsm, or about 300 gsm. This average basis weight may be substantially uniform along a length of the uninterrupted particulate stream 919. For example, the average basis weight may not vary along a length of the uninterrupted particulate stream 919 by more than about 15%, by more than about 10%, by more than about 5%, or may have no variance. In some embodiments, the average basis weight of the particulate material in the uninterrupted particulate stream 919 may not be higher than an upper range as, flowing the uninterrupted particulate stream 919 with a higher average particulate basis weight than this upper range may result in the adhesives 108a, 110a from the adhesive applicators 107a, 109a not being able to fully penetrate through a center of the uninterrupted particulate stream 919. For example, the upper range of the average particulate basis weight of the uninterrupted particulate stream 919 may be between about 200 gsm and 500 gsm, such as between about 250 gsm and 400 gsm, or about 300 gsm.

[0108] FIG. 9B depicts a partial view of the first particulate material deposition system 130a in a second state, where the first eductor system 160a emits a mixed fluid 902 to interrupt an interrupted particulate portion 921 between a first uninterrupted particulate portion 916 and a second uninterrupted particulate portion 917 from the deposition flow path A to define a first gap 924 therebetween. In some embodiments, another portion of the uninterrupted particulate stream 919 may have been previously interrupted such that the first deposition channel 845a may also include a third uninterrupted particulate portion 918 separate from the second uninterrupted particulate portion 917 to define a second gap 925 therebetween. In particular, the mixed fluid 902 may exit the first eductor system 160a with a greater kinetic energy than the portion of the uninterrupted particulate stream 919 that later becomes the interrupted particulate portion 921 to push the interrupted particulate portion 921 out of the deposition flow path A. For example, the mixed fluid 902 may exit the first eductor system 160a with a kinetic energy that is between about 50% and 800% greater than a kinetic energy of the uninterrupted particulate stream 919, such as between about 75% and 700%, such as between about 100% and 600%, such as between 125% and 400%, such as between about 150% and 200%, or the like. Additionally, the mixedPATENT109296-1411378-65084693PCT01 fluid 902 may exit the first eductor system 160a with a lesser pressure than the pressure of the motive fluids 923, 928 flowing into the valve channels 781, 783.

[0109] The interrupted particulate portion 921 may be received in the first return chute 115a for other uses. For example, the first return chute 115a may be in fluid communication with the uninterrupted particulate portions such that the interrupted particulate portion 921 may be recycled into the first particulate material reservoir 113a. Meanwhile, as the uninterrupted particulate portions 916, 917, 918 were not interrupted by the mixed fluid 902, the uninterrupted particulate portions 916, 917, 918 may continue flowing in the first deposition channel 845a to be deposited on a substrate (e.g., the first substrate layer 103 or the first absorbent layer 120a, as shown in FIG. 1, or the resilient layer 1030, as shown in FIG. 10B) having a pattern along a length of an absorbent core (e.g., the absorbent core 101, as shown in FIG. 1).

[0110] The interrupted particulate portion 921 may be forced out of flow path A with minimal disruption to the surrounding uninterrupted particulate portions 917, 918 (including the third uninterrupted particulate portion 918) because the mixed fluid 902 may exit the first mixed fluid outlet 667a with a fully developed velocity profile. In this manner, the uninterrupted particulate portions 916, 917, 918 may be deposited on the first substrate layer 103 having a very specific pattern that optimizes the performance of the absorbent core 101 and minimizes particulate material usage. The following description will describe generating the mixed fluid 902 to have a fully developed velocity profile.

[0111] The first eductor system 160a may form the mixed fluid 902 by mixing a first motive fluid 923 and a second motive fluid 928 with an ambient fluid 922. In particular, the control valves 791, 793 may be activated to release the motive fluids 923, 928 into the valve channels 781, 783. The motive fluids 923, 928 may flow out the valve channels 781, 783 and into the motive fluid channels 596a, 598a. The motive fluids 923, 928 may flow in the motive fluid channels 596a, 598a to the first mixed fluid inlet 672a and first suction outlet 470a. In particular, the first motive fluid 923 may flow in the first valve channel 781 and the first motive fluid channel 596a along a first motive flow path C. The second motive fluid 928 may flow in the second valve channel 783 and the eighth motive fluid channel 598a along a second motive flow path D.PATENT109296-1411378-65084693PCT01

[0112] When the motive fluids 923, 928 reach the first mixed fluid inlet 672a and first suction outlet 470a, a pressure differential is created between the suction channel 761 and motive fluid channels 596a, 598a at the first mixed fluid inlet 672a and first suction outlet 470a. Specifically, the motive fluids 923, 928 may provide a higher pressure at the first mixed fluid inlet 672a and first suction outlet 470a than the rest of the suction channel 761. This pressure differential may then pull in outside fluid (e.g. ambient fluid external to the eductor system 160a) into the suction channel 761. For example, this pressure differential may result in the first suction outlet 470a having a pressure less than the pressure of the ambient environment to pull in ambient fluid 922 into the first suction inlet 469a to flow into the suction channel 761. The ambient fluid 922 may flow through the suction channel 761 to the first suction outlet 470a along a suction flow path E.

[0113] The motive fluids 923, 928 and the ambient fluid 922 may begin to mix together at the first mixed fluid inlet 672a. The fluids 922, 923, 928 may continue intermixing as the fluids 922, 923, 928 flow through the mixed fluid channel 763 until a mixed fluid 902 exits the first mixed fluid outlet 667a through the first interruption window 857a and into the first deposition channel 845a. The mixed fluid 902 may exit the first mixed fluid outlet 667a with fully developed velocity profile (e.g., a laminar fluid flow or the like). In other words, the portion of the mixed fluid 902 exiting the first mixed fluid outlet 667a may have a substantially similar velocity and pressure along a cross-sectional profile of the mixed fluid 902. For example, this portion of the mixed fluid 902 may have a substantially similar velocity and pressure from a central point of the mixed fluid 902 (e.g., a center of the mixed fluid 902 aligned with a mixed fluid flow path B) toward the outer surface of the mixed fluid 902. As such, the mixed fluid 902 may have a fully developed velocity profile.

[0114] This fully developed velocity profile may be beneficial to ensure that the mixed fluid 902 can interrupt the uninterrupted particulate stream 919 shown in FIG. 9A while minimizing a vacuum pressure surrounding the mixed fluid 902. In this manner, the fully developed velocity profile of the mixed fluid 902 may minimize disruption of the flow of the surrounding portions of the uninterrupted particulate stream 919. As such, with reference to FIG. 9B, the mixed fluid 902 may force the interrupted portion 921 through the first bypass window 844a and into the first return chute 115a while minimizing the disruption caused by the passing of the mixed fluid 902 on the uninterrupted particulate portions 916, 917. In this manner, as will be described below,PATENT109296-1411378-65084693PCT01 when the uninterrupted particulate portions 916, 917 are later deposited on a substrate layer or mixture (e.g., the first substrate layer 103 or the first absorbent layer 120a, as shown in FIG. 1), the gap between the trailing end of the second uninterrupted particulate portion 917 (e.g., the upstream end of the second uninterrupted particulate portion 917) and the leading end of the first uninterrupted particulate portion 916 (e.g., the downstream end of the first uninterrupted particulate portion 916) may be free of particulate material. Additionally, the uninterrupted particulate portions 916, 917 may be deposited having a relatively even basis weight along their length.

[0115] In contrast, if the mixed fluid did not have a fully developed velocity profile, the flow of the surrounding uninterrupted particulate portions may be altered such that, when the uninterrupted particulate portions are deposited, the gap between the uninterrupted particulate portions may have some particulate material. Since, as will be described further below, in some embodiments, the gap between the deposited uninterrupted particulate portions may be removed during the production process, particulate material along that gap would be discarded and wasted rather than being reused. Further, as these gaps may be positioned in an absorbent article where exudate is unlikely to interact with the absorbent article, having particulate material in these gaps may be unnecessary and, therefore, wasteful. Additionally, the uninterrupted particulate portions may be deposited with an uneven thickness or basis weight. In particular, the edges of the uninterrupted portions may have an uneven thickness or basis weight, which can be wasteful (e.g., where the uninterrupted portions have a larger thickness than desired) or can lead to the formed absorbent article having suboptimal performance (e.g., where the uninterrupted portions have a smaller thickness than desired). The fully developed velocity profile of the mixed fluid 902 addresses these issues by minimizing the disruption of the flow of the uninterrupted particulate portions 916, 917. Accordingly, the fully developed velocity profile of the mixed fluid 902 can minimize waste and improve the performance of the formed absorbent article.

[0116] The motive fluids 923, 928 may exit the control valves 791, 793 into the valve channels 781, 783 at sufficient speeds to ensure that the ambient fluid 922 is pulled into first eductor system 160a at sufficient speeds to mix with the motive fluids 923, 928 and form the mixed fluid 902 having a fully developed velocity profile. For example, the motive fluids 923, 928 may be released (e.g., may enter the valve inlets 466a, 468a) at a velocity of between about 15 m / s andPATENT109296-1411378-65084693PCT0185 m / s, such as between about 25 m / s and 75 m / s, such as between about 35 m / s and 65 m / s, such as between about 45 m / s and 55 m / s, or the like. The ambient fluid 922 may be pulled into the first eductor system 160a at a velocity of between about 10 m / s and 75 m / s, such as between about 15 m / s and 65 m / s, such as between about 15 m / s and 55 m / s, such as between about 15 m / s and 45 m / s, or the like.

[0117] The first eductor system 160a may couple to the first deposition chute 140a at an angle such that the mixed fluid flow path B flows out of the first interruption window 857a and the eductor opening 843 to intersect the deposition flow path A at a point of intersection with an angle that minimizes the disruption the uninterrupted particulate portions 916, 917 by the mixed fluid 902. For example, the first eductor system 160a may couple to the first deposition chute 140a such that the mixed fluid flow path B and the deposition flow path A may have an angle of between about 50° and 130°, such as between about 60° and 120°, such as between about 70° and 110°, such as between about 80° and 100°, or about 90°. This angle may be beneficial to allow for the efficient transfer of energy from the mixed fluid 902 to the interrupted portion 921. Additionally, this angle may be beneficial in minimizing the risk that the mixed fluid 902 collides with a side wall of the first deposition chute 140a (e.g., the side walls 848, 858, shown in FIG. 8C). Additionally, this angle may minimize the risk that the mixed fluid 902 forces a portion of the interrupted portion 921 against the first deposition chute 140a such that a portion of the interrupted portion 921 remains within the first deposition channel 845a, rather than entering the first return chute 115a.

[0118] A first gap 924 may be defined between the uninterrupted particulate portions 916, 917 after the mixed fluid 902 forces the interrupted particulate portion 921 out of the first deposition chute 140a. A size of the first gap 924 may correspond, along with the specific dimensional configurations of the first mixed fluid outlet 667a, the first interruption window 857a, and the first bypass window 844a, with a length of time that the control valves 791, 793 release the motive fluid 923, 928 (e.g., a time between 1 ms and 20 ms, such as between about 2 ms and 15 ms, such as between about 3 ms and 10 ms, such as between about 4 ms and 5 ms, or the like) and, therefore, the length of time that the mixed fluid 902 interrupts the uninterrupted particulate stream (e.g., the uninterrupted particulate stream 919, as shown in FIG. 9A). For example, the second uninterrupted particulate portion 917 and a third uninterrupted particulate portion 918PATENT109296-1411378-65084693PCT01 may define a second gap 925 from a prior instance of the first eductor system 160a releasing the mixed fluid 902. As shown, the second gap 925 may be larger than the first gap 924 as the mixed fluid 902 may have been released for a first period of time to form the second gap 925 that was longer than a second period of time the mixed fluid 902 is released to form the first gap 924. Accordingly, the pattern of the deposited uninterrupted particulate portions 916, 917, 918 may be adjusted according to a length of time that the control valves 791, 793 release the motive fluid 923, 928 and the length of time the mixed fluid 902 is released. The gaps 924, 925 may include substantially no particulate material. This may include less than 15% of the average particulate basis weight of the uninterrupted particulate stream 919 (as shown in FIG. 9 A), such as less than about 12%, such has less than about 10% such as less than about 8%, such as less than about 6%, such as less than about 4%, or having no particulate material in the gaps 924, 925 (e.g., 0% particulate basis weight).

[0119] Once the mixed fluid 902 forces the interrupted particulate portion 921 out of the first deposition chute 140a along the mixed fluid flow path B, the uninterrupted particulate portions 916, 917 may exit the first deposition chute 140a along the deposition flow path A for further processing. For example, with reference to FIG. 1, the uninterrupted particulate portions may exit the deposition chutes 140a, 140b as streams 117a, 117b. Adhesive applicators 107a, 107b, 109a, 109a may apply adhesives 108a, 108b 110a, 110b on the streams 117a, 117b to form absorbent layers 120a, 120b. The absorbent layers 120a, 120b may be deposited on an underlying material layer. For example, the first absorbent layer 120a may be deposited on a first substrate layer 103 and the second absorbent layer 120b may be deposited on the first absorbent layer 120a (or an intervening layer, such as a resilient layer, that is positioned on the first absorbent layer 120a after the first absorbent layer 120a is deposited but before the second absorbent layer 120b is deposited). As the eductor systems 160a, 160b may interrupt a portion of the particulate stream flowing through the deposition chutes 140a, 140b, the absorbent layers 120a, 120b may be deposited on the underlying material layer in a pattern (e.g., having gaps defined along the absorbent layers 120a, 120b where the portions of the particulate stream were interrupted in the eductor systems 160a, 160b, such as corresponding to the gaps 924, 925, as shown in FIG. 9B). Each of the absorbent layers 120a, 120b may have the same pattern where the same streams of particulate material in the deposition chutes 140a, 140b are interrupted byPATENT109296-1411378-65084693PCT01 the eductor systems 160a, 160b at the same locations. However, in other embodiments, one of the absorbent layers may have a different pattern from each other.

[0120] Various patterns may be formed along the initial material layer using the method described above. By controlling which deposition channels (e.g., the deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g, as shown in FIGS. 8A and 8B) have their stream of particulate material interrupted, the absorbent core 101 can have a certain pattern as defined along a Y-axis. For example, to form a first absorbent layer 120a with a pattern where only an interior-most portion of the first absorbent layer 120a includes particulate material (e.g., SAM or the like), one or more streams of particulate material flowing in the deposition chutes 140a, 140b may be interrupted, as discussed below. In one example, with reference to FIGS. 4A and 4B, the motive fluid may be released into the valve inlets 466a, 466b, 466f, 466g, 468a, 468b, 468f, 468g to flow out of the valve outlets 486a, 486b, 486f, 486g, 487a, 487b, 487f, 487g. The motive fluid may flow toward the suction outlets 470a, 470b, 470f, 470g (e.g., through the motive fluid channels 596a, 596b, 596f, 596g, 598a, 598b, 598f, 598g, as shown in FIG. 5). As the motive fluid reaches the suction outlets 470a, 470b, 470f, 470g, ambient fluid may be pulled into the suction inlets 469a, 469b, 469f, 469g and exit the suction outlets 470a, 470b, 470f, 470g. With reference to FIGS. 6A and 6B, the ambient fluid and the motive fluid may enter the mixed fluid inlets 672a, 672b, 672f, 672g to mix and form a fully developed velocity profile. This mixed fluid may exit the mixed fluid outlets 667a, 667b, 667f, 667g (e.g., as a mixed fluid 902, shown in FIG. 9B). With reference again to FIGS. 8A and 8B, the mixed fluids may interrupt the particulate streams flowing within the deposition channels 845a, 845b, 845f, 845g such that only the particulate materials in the deposition channels 845c, 845d, 845e exits the chute outlets 842c, 842d, 842e uninterrupted. In this manner, an absorbent layer may be deposited on top of an initial material layer such that only a central portion of the underlying layer includes particulate material of the absorbent layer positioned thereon. However, in other embodiments, a absorbent layer having any pattern of particulate matter may be formed on the initial material layer by interrupting a stream of particulate material through any combination of the deposition channels through the above-described methods (e.g., interrupting a stream of particulate material flowing in the central deposition channels 845c, 845d, 845e such that the absorbent layer only includes particulate material exiting the outer deposition channels 845a, 845b, 845f, 845g, or the like).PATENT109296-1411378-65084693PCT01

[0121] The pattern of the first absorbent layer 120a along its length can be adjusted by controlling an amount of time that a mixed fluid is released from the control valves. For example, with reference to FIG. 9B, the control valves 791, 793 may be actuated to release the motive fluids 923, 928 for a first period of time to interrupt the particulate stream (e.g., the uninterrupted 919, shown in FIG. 9A) to define the first gap 924 and for a second period of time to interrupt the particulate stream to define the second gap 925. Specifically, the second period of time may be longer than the first period of time such that the second gap 925 may be larger than the first gap 924. In this manner, for each deposition channel (e.g., the deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g, as shown in FIGS. 8A and 8B), gaps of different lengths may be formed. Accordingly, by controlling which deposition channels have their stream of particulate material interrupted and how long each stream of particulate material is interrupted in each deposition channel, an absorbent layer (e.g., the absorbent layers 120a, 120b, as shown in FIG. 1) may be deposited on an initial material layer having a customizable pattern of particulate material along a width and length of an absorbent core (e.g., the absorbent core 101, as shown in FIG. 1).

[0122] As noted above, with reference to FIG. 1, forming the absorbent layers 120a, 120b to have a pattern can be beneficial to save material costs while minimizing performance loss of the absorbent article. For example, after the absorbent cores 101 are formed with one or more of the absorbent layers are 120a, 120b having a pattern, the absorbent core 101 can be further processed to form an absorbent article (e.g., positioned between covers to form an absorbent article). As will be described further below, patterns of the absorbent layers formed by the particulate material deposition systems 130a, 130b can optimally concentrate particulate material along the absorbent article where the particulate material is most likely needed for absorption (e.g., where the absorbent article is most likely going to be exposed to exudate) and to be excluded where particulate material is less likely to be required. Whereas conventional absorbent articles may form a composition having a pattern through inefficient means (e.g., by wastefully cutting and discarding portions of the deposited mixture, or forming the pattern by pushing or blowing the deposited particulate material such that the particulate material has uneven clumps, leading to suboptimal absorption / retention performance of the absorbent article), the particulate material deposition systems 130a, 130b can form absorbent articles to have a desired pattern withoutPATENT109296-1411378-65084693PCT01 wasting particulate material (e.g., by recycling particulate material through the return chutes 115a, 115b) and with patterns that do not sacrifice (or even improve) the performance of the absorbent article.

[0123] FIGS. 10A and 10B depict a top view of an absorbent article 1000 including an absorbent core 101. It should be understood that the absorbent article 1000 may include more or fewer components than shown, however, certain components (e.g., additional mechanical fastening components or the like) are not depicted for the sake of brevity. The absorbent article 1000 can include a first cover 1038, a second cover 1040, and the absorbent core 101 positioned between the first cover 1038 and the second cover 1040. The dashed lines overlaid on the second cover 1040 may represent features of the absorbent article 1000 below the second cover 1040. For illustrative purposes, the second cover 1040 may include a cut-out 1042 exposing the features of the absorbent article 1000 below the second cover 1040, including a portion of the absorbent core 101 and the first cover 1038. The covers 1038, 1040 may be constructed of a single layer, multiple layers, laminates, spunbond fabrics, films, meltblown fabrics, elastic netting, microporous webs, bonded-carded webs or foams provided by elastomeric or polymeric materials.

[0124] In use, the second cover 1040 may be configured to contact a user’s body (e.g., a body side liner) and the first cover 1038 may be an outer surface of the absorbent article 1000 (e.g., an outer cover). The absorbent core 101 may absorb and retain exudate from the user. The term “user” refers herein to one who fits an absorbent article, such as, but not limited to, a diaper, diaper pant, training pant, youth pant, incontinent product, or other absorbent article about the wearer of one of these absorbent articles. A user and a wearer can be one and the same person.

[0125] The absorbent article 1000 may include leg elastics 1044 located generally at the longitudinal edges of the absorbent article 1000. The absorbent article 1000 may include a first fastening tab 1010 and a second fastening tab 1012 used to couple a rear waist portion 1048 to a front waist portion 1046. For example, the tabs 1010, 1012 can couple to the front waist portion 1046 through a hook-and-fastener mechanism, adhesive, or other means of coupling means. Although the absorbent article 1000 is depicted as a diaper, it is understood that, in otherPATENT109296-1411378-65084693PCT01 embodiments, the absorbent articles can be other types of product, such as a hygienic pad or the like.

[0126] As noted above, the absorbent core 101 may include particulate material formed to have a variety of desired shapes along the X-Y plane. In particular, the absorbent core 101 may be defined to concentrate particulate material in certain locations to optimize exudate absorption and retention while leaving gaps in other locations. These patterns may save costs on particulate material (e.g., SAM or the like) usage and also allow for the absorbent article 1000 to more easily be formed to a desired shape with the shape of the absorbent core 101 (e g., more easily shape leg cut-outs where the absorbent core 101 includes gaps for those leg cut-outs).

[0127] For example, FIG. 10B depicts a simplified cross-sectional view of the absorbent article 1000 along Section D-D. The absorbent core 101 may include a composition comprising a first absorbent layer 1020, a resilient layer 1030, and a second absorbent layer 1022, and an adhesive layer 1026. This composition may be positioned in an absorbent material region 1050 defined between a first material layer 1003 and a second material layer 1024. As noted above, one or more of the absorbent layers 1020, 1022 (e.g., both of the absorbent layers 1020, 1022) can each be made of a substantially similar material. In some embodiments, one or more of the absorbent layers 1020, 1022 (e.g., both of the absorbent layers 1020, 1022) can be substantially pulp-free. In some embodiments, the particulate material of the absorbent layers 1020, 1022 may be substantially entirely SAM. The absorbent core 101 may include a basis weight of particulate material of between about 100 gsm and 1000 gsm, such as between about 200 gsm and 700 gsm, such as between about 300 gsm and 600 gsm, or about 400 gsm. The absorbent core 101 may be similar to the absorbent core 101, as shown in FIG. 1. As such, the layers of the absorbent core 101 may correspond to the above description of the substrate layers 103, 124, absorbent layers 120a, 120b, and adhesives 108b, 110b after being cut into the individual absorbent cores 101 by the cutting station 129. Although not shown in FIG. 1, a resilient layer may have been provided during the formation of the absorbent core 101 such that the resilient layer 1030 corresponds to a resilient layer after being cut by the cutting station 129.

[0128] The lateral ends (e.g., the ends along the X-axis) of each of the material layers 1003 1024 and the absorbent layers 1020, 1022 may correspond to areas where the substrate layersPATENT109296-1411378-65084693PCT01103, 124 and the absorbent layers 120a, 120b are cut by the cutting station 129. For example, the material layers 1003, 1024, with continued reference to FIG. 1, may correspond to the substrate layers 102, 124 after being cut and the absorbent layers 1020, 1022 may correspond to the absorbent layers 120a, 120b after being cut. In some embodiments, the lateral ends of the layers 1003, 1020, 1022, 1024 may correspond to lateral edges of the absorbent core 101.

[0129] The second absorbent layer 1022 may be positioned between the resilient layer 1030 and the second material layer 1024. The second absorbent layer 1022 may include a changing thickness and may define a gap 1029 corresponding to interruptions in the stream of particulate material during formation of the absorbent core 101 . For example, the second absorbent layer1022 may include a body portion 1023 having a length defined between a first body end 1028 and a second body end 1034. This length may be between about 40% and 87% of a longitudinal length of the absorbent core 101 (e.g., along the X-axis), such as between about 50% and 70%, or about 60%. It may be important to locate the body portion 1023 such that a first body end 1028 of the body portion 1023 is at an X-direction location from a front waist edge of the absorbent article 1000 of between about 3% and about 8% of a total length of the absorbent article 1000, such as between about 3.5% and about 7%, or such as between about 4% and about 6%. The body portion 1023 may have a substantially similar thickness along its length in the X- axis (e.g., a thickness with a variance along the length of the body portion 1023 that is less than about 15%, less than about 10%, less than about 5%, or may have no variance). The body portion1023 can have a substantially uniform particulate material basis weight along the length and width of the body portion 1023 (e.g., the average basis weight may have a variance along a length of the body portion 1023 of less than about 15% of an average particulate material basis weight of the body portion 1023, less than about 10%, less than about 5%, or may have no variance). However, in other embodiments, the body portion may not have a consistent thickness.

[0130] The second absorbent layer 1022 may include a first transition portion 1021 extending between a first transition end 1060 and a second transition end 1062 coupled to the first body end 1028 of the body portion 1023, a second transition portion 1025 extending between a third transition end 1064 coupled to the second body end 1034 to a fourth transition end 1066, and a third transition portion 1027 extending from a fifth transition end 1068 to a sixth transition endPATENT109296-1411378-65084693PCT011070. The first transition end 1060 may correspond with a first lateral edge of the absorbent core 101 and the sixth transition end 1070 may correspond with a second lateral edge of the absorbent core. The transition portions 1021, 1025, 1027 may correspond to the trailing and leading ends of an uninterrupted portion of a stream of particulate material after an eductor system has interrupted portions of the stream of particulate material flowing in a deposition chute. For example, the second transition portion 1025 may correspond to a downstream end of an uninterrupted portion of a particulate stream (e.g., a downstream end of the uninterrupted particulate portion 916, shown in FIG. 9B), and the first transition portion 1021 and the third transition portion 1027 may collectively correspond to an upstream end of an uninterrupted portion of a particulate stream (e.g., an upstream end of the uninterrupted particulate portion 917, shown in FIG. 9B). For example, during formation of the absorbent core 101, a deposited portion of an absorbent layer may be cut by a cutting machine such that, on one side of the cut is the leading end of an absorbent layer (e.g., the first transition portion 1021) and on the other side is the trailing end of an absorbent layer (e.g., the third transition portion 1027). In this manner, the transition portions 1021, 1027 may include similar particulate material basis weight slope values, as discussed further below.

[0131] The first transition portion 1021 may include a first length (along the X-axis) defined between the transition ends 1060, 1061 of between about 2% and 25% of a longitudinal length of the absorbent core 101, such as between about 3.5% and 20%, such as between about 5% and 15%, such as between about 6.5% and 10%, or the like. The second transition portion 1025 may include a second length (along the X-axis) defined between the transition ends 1064, 1066 of between about 5% and 50% of a longitudinal length of the absorbent core 101, such as between about 6.5% and 35%, such as between about 6.5% and 25%, such as between about 10% and 20%, or about 15%. The third transition portion 1027 may include a third length (along the X- axis) defined between transition ends 1068, 1070 of between about 0% and 47% of a longitudinal length of the absorbent core 101, such as between about 1% and 30%, such as between about 2.5% and 25%, such as between about 3.5% and 20%, such as between about 5% and 15%, or about 10%.

[0132] The fourth transition end 1066 of the second transition portion 1025 and the fifth transition end 1068 of the third transition portion 1027 may define a gap 1029 therebetween thatPATENT109296-1411378-65084693PCT01 corresponds to a space defined between the uninterrupted portions 916, 917 by the interrupted portion 921 being forced out (as shown in FIG. 9B), such as the gaps 924, 925. Accordingly, the gap 1029 may include less than 15% of the average particulate material basis weight of the body portion 1023, such as less than about 12%, such as less than about 10% such as less than about 8%, such as less than about 6%, such as less than about 4%, or having no particulate material (e.g., 0% particulate material basis weight). Additionally, the gap 1029 may include less than 15% of the average particulate material basis weight of the absorbent core 101, such as less than about 12%, such as less than about 10% such as less than about 8%, such as less than about 6%, such as less than about 4%, or having no particulate material.

[0133] As discussed above, the second absorbent layer 1022 may be formed to have a changing thickness along the X-axis and to define the gap 1029 to decrease the usage of particulate material (e.g., SAM or the like) and save on material costs while also providing effective exudate absorption and retention qualities for the absorbent article 1000. For example, rather than the second absorbent layer 1022 having a consistent thickness along its length on the X-axis, the second absorbent layer 1022 may have less particulate material along the transition portions 1021, 1025, 1027 and no particulate material in the gap 1029 to save on material costs. At the same time, concentrating particulate material at the body portion 1023, while also providing some particulate material in the transition portions 1021, 1025, 1027 can provide an effective amount of exudate absorption and retention qualities for the absorbent article 1000. Accordingly, forming the absorbent core 101 through the particulate material deposition systems described may form the absorbent core 101 to optimize the cost and performance of the absorbent article 1000.

[0134] The transition portions 1021, 1025, 1027 may each have a particulate material basis weight slope (e.g., a rate of change in basis weight along a length of the transition portions 1021, 1025, 1027) corresponding to the deposition of the trailing and leading ends of an uninterrupted portions of a stream of particulate material on a moving surface. The particulate material basis weight slope may be calculated as a function of two points - a first point being a point at a first end of a given transition portion 1021, 1025, or 1027 and a second point being at a second end of the given transition portion 1021, 1025, or 1027. For example, the particulate material basis weight slope of each transition portion 1021, 1025, 1027 may correspond to, with reference toPATENT109296-1411378-65084693PCT01FIG. 1, particulate material basis weight slopes of the ends of the uninterrupted portions in the second stream 117b being deposited on the first absorbent layer 120a or intervening layer as the first absorbent layer 120a or intervening layer is moved along the machine direction 104 at a certain speed. Additionally, the particulate material basis weight slopes of each transition portion 1021, 1025, 1027 may correspond to how thoroughly, with reference to FIG. 9B, the interrupted portion 921 is separated from the uninterrupted portions 916, 917 by the mixed fluid 902 given the speed of production of each article. As noted above, if the mixed fluid 902 were not a fully developed velocity profile, the ends of the uninterrupted portions 916, 917 would have an uneven shape that can result in an inefficient deposition of particulate material. As such, with reference back to FIG. 10B, the absorbent article formation systems described in this disclosure may form the absorbent core 101, while at high speeds (e.g., greater than 600 ppm, 700 ppm, 800 ppm or the like), to have absorbent layers 1020, 1022 to have a particular pattern and cross-sectional profile (e.g., including the gap 1029 and transition portions 1021, 1025, 1027) that maximizes exudate absorption and retention and minimizes particulate material usage.

[0135] The first transition portion 1021 may include a first particulate material basis weight slope, in a first direction from the first transition end 1060 to the second transition end 1062, of between about 0.5 gsm / mm and 10 gsm / mm, such as between about 0.75 gsm / mm and 8 gsm / mm, such as between about 1 gsm / mm and 6 gsm / mm, such as between about 1.5 gsm / mm and 4 gsm / mm, such as between about 2 gsm / mm and 3.5 gsm / mm, or about 3 gsm / mm. As noted above, the first transition portion 1021 and the third transition portion 1027 may include a similar particulate material basis weight slope. As such, the third transition portion 1027 may include a third basis weight slope, in a third direction from the fifth transition end 1068 to a sixth transition end 1070, having substantially similar values as the first basis weight slope. However, in other embodiments, the first and third basis weight slopes may be different. The second transition portion 1025 may include a second particulate material basis weight slope, in a second direction from the third transition end 1064 to the fourth transition end 1066, of between about - 0.4 gsm / mm and -13 gsm / mm, such as between about -0.5 gsm / mm and -11 gsm / mm, such as between about -0.6 gsm / mm and -9 gsm / mm, such as between about -0.7 gsm / mm and -7 gsm / mm, such as between about -0.8 gsm / mm and -5 gsm / mm, such as between about -0.9 gsm / mm and -3 gsm / mm, or about -2 gsm / mm.PATENT109296-1411378-65084693PCT01

[0136] The particulate material basis weight slopes for the transition portions 1021, 1025, 1027 may be derived using a basis weight sensor. Additionally or alternatively, an operator may manually measure the basis weight profile by sectioning off the transition portions 1021, 1025, 1027 into a plurality of segments along a length of the transition portions 1021, 1025, 1027 (e.g., into at least 10 segments, preferably at least 15 segments, preferably at least 30 segments, preferably at least 40 segments, or more) having a certain width (e.g., between about 1 1 mm and 13 mm, or the like) - for example, by carefully cutting sections of the absorbent core 101 with a cutting mechanism, such as a sharp fabric scissors, rotary cutter, or the like. The absorbent core 101 may be removed from an absorbent article with the use of freeze-spray or the like, as is common in the art. Each of these segments can be measured to determine a particulate material basis weight of each segment and these measurements can be aggregated to determine a particulate material basis weight profile.

[0137] The second transition portion 1025 may have a different particulate material basis weight slope in absolute terms (e.g., the numerical value without regard to its positive or negative sign) than the particulate material basis weight slope of the transition portions 1021, 1027. In particular, the absolute value of the particulate material basis weight slope of the second transition portion 1025 can be less than the absolute value of the particulate material basis weight slope of the transition portions 1021, 1027. However, in other embodiments, the first and / or third transition portion may have a lesser particulate material basis weight slope than the second transition portion.

[0138] The particulate material basis weight slopes may include a negative or positive value corresponding to a rate of change in particulate material basis weight in a particular direction along the X-axis, such as, as shown in FIG. 10B, from a left-most lateral edge of the absorbent core 101 to a right-most lateral edge of the absorbent core 101. In this manner, the basis weight of the first transition portion 1021 may increase from a first minimum at the first transition end 1060 to a first peak (e.g., a maximum) at the second transition end 1062, the basis weight of the second transition portion 1025 may decrease from a second peak at the third transition end 1064 to a second minimum at the fourth transition end 1066, and the basis weight of the third transition portion 1027 may increase from a third minimum at the fifth transition end 1068 to a third peak at the fourth transition end 1070. Further, the locations of the peaks of the transitionPATENT109296-1411378-65084693PCT01 portions 1021, 1025, 1027 can correspond with the locations of the peaks of the second absorbent layer 1022 while the locations of the minimums of the transition portions 1021, 1025, 1027 can correspond with the locations of the minimums of the second absorbent layer 1022.

[0139] The average basis weights (e.g., average particulate material basis weight) of the various portions 1021, 1023, 1025, 1027 can be different. For example, the average basis weight of the body portion 1023 can be larger than one or more of the transition portions 1021, 1025, 1027. In some embodiments, the average basis weight of the body portion 1023 can be larger than all of the transition portions 1021, 1025, 1027. However, in other embodiments, the average basis weights of one or more of the transition portions (including a combination of the transition portions) may be larger than the average basis weight of the body portion. Additionally one or more of the transition portions 1021, 1025, 1027 can have an average basis weight (e.g., average particulate material basis weight) that is different than the others. For example, the first transition portion 1021 can have a larger average basis weight than the second transition portion 1025. Additionally or alternatively, the third transition portion 1027 can have a smaller average basis weight relative to the first transition portion 1021 and the third transition portion 1027 can have a larger, smaller, or similar average basis weight relative to the second transition portion 1025 according to the needs of the article 1000. However, in some embodiments, the third transition portion 1027 can have a smaller average basis weight relative to the second transition portion 1025.

[0140] The body portion 1023 can include an average basis weight of between about 50 gsm and 500 gsm, such as between about 75 gsm and 350 gsm, such as between about 100 gsm and 300 gsm, such as between about 150 gsm and 200 gsm, or the like. The first transition portion1021 can include an average basis weight of between about 50% to 95% of the average basis weight of the body portion 1023, such as between about 60% to 95%, or between about 75% to 95%. The second transition portion 1025 can include an average basis weight of between about 20% to 75% of the average basis weight of the body portion 1023, such as between about 25% to 65%, or between about 35% to 55%. The third transition portion 1027 can include an average basis weight of between about 20% to 75% of the average basis weight of the body portion 1023, such as between about 25% to 65%, or between about 35% to 55%. The second absorbent layer1022 can include an average basis weight of between about 20 gsm and 250 gsm, such asPATENT109296-1411378-65084693PCT01 between about 50 gsm and 200 gsm, such as between about 50 gsm and 175 gsm, such as between about 75 gsm and 150 gsm, or the like.

[0141] Additionally, the absorbent article formation systems described in this disclosure may form the absorbent layers 1020, 1022 to have a particular absolute weight profile of particulate material along a length of the absorbent core 101. For example, the first transition portion 1021 may include a first weight of particulate material between about 0.15 g and 0.6 g, such as between about 0.2 g and 0.55 g, such as between about 0.25 g and 0.5 g, such as between about 0.3 g and 0.45 g, or about 0.4 g. The body portion 1023 may include a second weight of particulate material between about 1.5 g and 5.5 g, such as between about 2 g and 5 g, such as between about 2.5 g and 4.5 g, such as between about 3 g and 4 g, or about 3.5 g. The second transition portion 1025 may include a third weight of between about 0.2 g and 0.8 g, such as between about 0.3 g and 0.7 g, such as between about 0.4 g and 0.6 g, or about 0.5 g. The absorbent article 1000 may have a total weight of particulate material that is less than about fo g, such about 10 g, such as less than about 5 g, or the like. The third transition portion 1027 may include a fourth weight of between about 0.05 g and 1.8 g , such as between about 0.1 g and 1.5 g, such as between about 0.25 g and 1.25 g, such as between about 0.4 g and 1.0 g, or about 0.5 g-

[0142] The portions 1021, 1023, 1025, 1027 may have a relative particulate material weight profile along a length of the absorbent core 101. For example, the particulate material of the body portion 1023 can be between 30% and 95% of a total amount of particulate material of the second absorbent layer 1022, such as between about 40% and 90%, such as between about 50% and 80%, such as between about 55% and 70%, or the like. The particulate material of the body portion 1023 can be between 15% and 45% of a total amount of particulate material of the absorbent core 101, such as between about 25% and 35%, or about 30%. The first transition portion 1021 can be between about 2% and 25% of a total amount of particulate material of the second absorbent layer 1022, such as between about 3.5% and 20%, such as between about 5% and 15%, such as between about 6.5% and 10%, or the like. The second transition portion 1025 can be between about 5% and 25% of a total amount of particulate material of the second absorbent layer 1022, such as between about 6% and 20%, such as between about 7% and 15%, such as between about 8% and 10%, or the like. The third transition portion 1027 can be betweenPATENT109296-1411378-65084693PCT01 about 0.05% and 20% of a total amount of particulate material of the second absorbent layer 1022, such as between about 0.5% and 15%, such as between about 1.0% and 15%, such as between about 2.5% and 10%, or the like.

[0143] In certain embodiments, it may be important for the different portions 1021, 1023, 1025, 1027 to have particular relative basis weights depending on the steepness or shallowness of the basis weight transition slopes of the second and third transition portions 1025, 1027. For example, where the absolute value of the basis weight transition slopes of the second and / or third transition portions 1025, 1027 are relatively steep, such as greater than about 3.25 gsm / mm, it may be important for the length of the body portion 1023 to be greater than 70% of a total length of the second absorbent layer 1022, such as between about 70% and about 85%, such as between about 70% and about 80%, or such as between about 75% and about 80%. In these embodiments, it may additionally be important for the body portion 1023 to have a percentage of the total SAM of the second absorbent layer 1022 greater than about 92.5%, such as greater than about 94%, such as greater than about 95%, or such as greater than about 96%.

[0144] Where the absolute value of the basis weight transition slopes of the second and / or third transition portions 1025, 1027 are relatively shallow, such as less than about 1.0 gsm / mm, it may be important for the length of the body portion 1023 to be less than about 60% of a total length of the second absorbent layer 1022, such as between about 45% and about 60%, such as between about 45% and about 55%, or such as between about 50% and about 55%. In these embodiments, it may additionally be important for the body portion 1023 to have a percentage of the total SAM of the second absorbent layer 1022 greater than about 82.5%, such as between about 85% and about 90%, such as between about 86.5% and about 89%, or such as between about 86.5% and about 88%.

[0145] Where the absolute value of the basis weight transition slopes of the second and / or third transition portions 1025, 1027 are in between 1.0 gsm / mm and 3.25 gsm / mm, it may be important for the length of the body portion 1023 to be between about 60% and 70% of a total length of the second absorbent layer 1022. In these embodiments, it may additionally be important for the body portion 1023 to have a percentage of the total SAM of the secondPATENT109296-1411378-65084693PCT01 absorbent layer 1022, such as between about 90% and about 95%, such as between about 90% and about 9.25%, or the like.

[0146] The above value combinations ensure that the body portion 1022 has an appropriate absorbent capacity in a desired location to optimally satisfy absorbency and leakage requirements of the absorbent article 1000. Embodiments in accordance with the present disclosure therefore satisfy absorbency and leakage requirements while combinations outside of the disclosed range combinations may result in a lowered total absorbent capacity and / or increased leakage rates.

[0147] The first absorbent layer 1020 may be positioned between the resilient layer 1030 and the first material layer 1003. The first absorbent layer 1020 may have a substantially uniform thickness along a length of the first absorbent layer 1020 along the X-axis (e.g., a thickness change along the length of the first absorbent layer 1020 of less than about 5%, less than about 4%, less than about 3%, less than about 2%, less than about 1%, or being completely uniform). The first absorbent layer 1020 may include a particulate material basis weight variation (e.g., a percentage variation of particulate material basis weight per unit volume of the first absorbent layer 1020) of less than about 5% of an average particulate material basis weight of the first absorbent layer 1020, such as less than about 4%, less than about 3%, less than about 2%, less than about 1%, or having no variation. However, in other embodiments, the first absorbent layer (e.g., the first absorbent layer 1020) may not have a consistent thickness along its length. For example, the first absorbent layer may have a changing thickness, similar to the second absorbent layer (e.g., the second absorbent layer 1022) (e.g., including a pattern and defining one or more gaps). In yet other embodiments, the first and second absorbent layers may each have a similar shape. For example, the first absorbent layer and the second absorbent layer may be substantially similar in that they have the same pattern and define the same gaps such that the first absorbent layer and the second absorbent layer have substantially the same thicknesses at the same relative locations in the x-direction. In even further embodiments, the second absorbent layer may have a substantially similar thickness along a length of the second absorbent layer while the first absorbent layer may have a changing thickness and / or may define gaps.PATENT109296-1411378-65084693PCT01

[0148] The absorbent core 101 may include adhesive uniformly distributed throughout the absorbent core 101. For example, the absorbent layers 1020, 1022 may include adhesive uniformly distributed throughout the absorbent layers 1020, 1022. The first absorbent layer 1020 may include adhesives 108a, 110a (as shown in FIG. 1) uniformly distributed with particulate material and the second absorbent layer 1022 may include adhesives (e.g., the adhesives 108b, 110b shown in FIG. 1) uniformly distributed with particulate material. The adhesives may be uniformly distributed throughout the absorbent layers 1020, 1022 such that the distribution of adhesive (by basis weight) along a length and width of the absorbent layers 1020, 1022 may have a variance of less than about 15% of an average adhesive basis weight of the absorbent layers 1020, 1022, by less than about 10%, by less than about 5%, or may not vary at all. The absorbent layers 1020, 1022 may include a ratio of adhesive to particulate material (by basis weight percentage) of between about 1% and 10%, such as between about 1.5% and 8%, such as between about 2% and 6%, such as between about 2.5% and 5%, such as between about 3% and 4%, or about 3.5%. The absorbent core 101 may include an adhesive layer 1026 (e.g., corresponding to adhesives 108b, 110b, as shown in FIG. 1) positioned in the gap 1029. In other embodiments, where the first absorbent layer includes one or more gaps, the first absorbent may also still include a continuous adhesive layer. In this manner, the absorbent core 101 can include adhesive continuously disposed along the second absorbent layer 1026 (e.g., along a length of the absorbent core 101 along an X-axis).

[0149] This continuous distribution may be a result of the absorbent article formation system of this disclosure forming the shape of the second absorbent layer 1022 while still providing adhesives 108b, 110b from the adhesive applicators 107b, 110b. In particular, with reference to FIG. 1, the adhesive applicators 107b, 110b may continue providing adhesives 108b, 110b as the second stream 117b of particulate material flows past the adhesive applicators 107b, 110b, even after the second eductor system 160b interrupts portions of the stream of particulate material in the second deposition chute 140b. In this manner, the adhesive applicators 107b, 110b can continuously provide the adhesives 108b, 110b even where the stream of particulate material is interrupted. A similar process may be performed for the adhesive applicators 107a, 109a and the first stream 117a of particulate material.PATENT109296-1411378-65084693PCT01

[0150] Turning back to FIG. 10B, the continuous distribution of adhesive in the absorbent layers 1020, 1022 may also result in a substantially uniform distribution of adhesive throughout the absorbent core 101, as noted above. For example, adhesives may be uniformly distributed throughout the absorbent core 101 with a uniformity index (UI) of greater than about 0.8, a UI of greater than about 0.9, or a completely uniform distribution of adhesives throughout the absorbent core 101 . Additionally or alternatively, the absorbent core 101 may include an adhesive basis weight variation (e.g., a percentage variation of adhesive basis weight per unit volume) throughout the absorbent core 101 of less than about 5%, less than about 4%, less than about 3%, less than about 2%, less than about 1%, or having no variation. In other words, each portion of the absorbent core 101 may include an adhesive basis weight that is within this noted adhesive basis weight variation (e.g., without about 5%, within about 4%, within about 3%, within about 2% within about 1%, or being completely the same) of an average amount of adhesive basis weight of the absorbent core 101. The absorbent article 1000 may also include similar distribution uniformity of the adhesives throughout the absorbent material region 1050. In this manner, the uniform distribution of adhesive (and adhesive layer 1026) improves the coupling strength between the layer underlying the second absorbent layer 1022 (e.g., the resilient layer 1030 in this embodiment) with the second material layer 1024. Whereas conventional absorbent article formation systems may form absorbent layers having a particular shape in a manner that may remove certain portions of the adhesive layers, such as through trimming the layers, the present design includes adhesive on all portions of layers underlying the second absorbent layer 1022 to improve the structural integrity of the absorbent core 101 even where portions of the absorbent layers 1020, 1022 includes gaps, such as the gap 1029.

[0151] In other embodiments, with reference to FIG. 1, the adhesive applicators (e.g., applicators 107a, 107b 109a, 109b) may provide adhesive (e.g., adhesive 108a, 108b, 110a, 110b) only onto uninterrupted portions of particulate material such that there is no adhesive layer (e.g., adhesive layer 1026, as shown in FIG. 10B) positioned in the gap (e.g., gap 1029, as shown in FIG. 10B) between separate portions of an absorbent layer (e.g., transition portions 1025, 1027, as shown in FIG. 10B). For example, the absorbent article formation system may include adhesive applicators corresponding to each deposition channel of the deposition chutes. A computer system can instruct each adhesive applicator to provide adhesives only on thePATENT109296-1411378-65084693PCT01 uninterrupted portions of particulate material by activating the adhesive applicators when an uninterrupted portion of a particulate stream is falling past the adhesive applicators and not activating the adhesive applicators when there is no particulate material falling past the adhesive applicators. In one example, the adhesive applicators may be deactivated based on a time from when the valves in the eductor system were activated. In this manner, the adhesive applicators can deactivate when the valves in the eductor system activate while accounting for the time that the uninterrupted portions of particulate material may fall. In yet other examples, image sensors may be used to receive image data of the falling streams of particulate material and the adhesive applicators may be instructed to activate or deactivate based on whether the image data indicates that there are gaps between uninterrupted portions of particulate material (e.g., using computer vision or the like). The adhesive applicators corresponding to those gaps may be instructed to deactivate based on those detected gaps in the image data.

[0152] The absorbent article 1000 may include a resilient layer 1030. The resilient layer 1030 may provide structural rigidity to the absorbent article 1000. For example, the resilient layer 1030 may include a non-woven material comprised of multiple individual fibers, such as a spunbond material or a spunbond-meltblown-spunbond (SMS) material. In other embodiments, the resilient layer 1030 may be a porous nonwoven material, such as a through-air bonded carded web (TABCW) or chemically bonded nonwoven materials or the like. In still further embodiments, the resilient layer 1030 may include a spunlace material, including combinations of TABCW materials with Rayon fibers or SMS materials with Rayon fibers. In still further embodiments, the resilient layer 1030 may be comprised substantially of polyolefin bicomponent fibers, or polyolefin mixed bi-component and eccentric fibers, or just polyolefin eccentric fibers. In some specific preferred examples, a TABCW material may be used comprising between 60% to 80%, by weight, eccentric bi-component fibers (comprising polyethylene and polypropylene) having a denier of between about 3 and about 7 and between 20% and 40%, by weight, non-eccentric bi-component fibers (comprising polyethylene and polypropylene) having a denier of between about 1 and about 3. Although, it should be understood that these are just some exemplary materials. Other suitable materials may be used in other contemplated embodiments. The resilient layer 1030 may have a preferred basis weight between about 10 gsm to about 120 gsm. In more specific embodiments, the reinforcing webPATENT109296-1411378-65084693PCT01 material 329 may have a basis weight of between about 10 gsm to about 100 gsm, or between about 10 gsm to about 90 gsm, or between about 10 gsm to about 80 gsm, or between about 10 gsm to about 70 gsm, or between about 20 gsm to about 70 gsm, or between about 30 gsm to about 70 gsm, or any other suitable basis weight. However, in other embodiments, the absorbent article may not include a resilient layer. In this example, the adhesive layer (e.g., the adhesive layer 1026) may be positioned between the second material layer (e.g., the material layer 1024) and the first absorbent layer (e.g., the first absorbent layer 1020) in the gap (e.g., the gap 1029) defined between the second transition portion (e.g., the second transition portion 1025) and the third transition portion (e.g., the third transition portion 1027) of the second absorbent layer (e.g., the second absorbent layer 1022).

[0153] As noted above, the absorbent article formation systems of the present disclosure may form the second absorbent layer 1022 to have a variety of patterns based on which deposition channel is interrupted to determine a pattern of gaps along a width-wise direction (e.g., a Y- direction, as shown in FIG. 1) and how long that interruption is for to determine a length of each gap along a length-wise direction (e.g., an X-direction, as shown in FIG. 1). These patterns may optimize various performance features of the absorbent article 1000 (e.g., one or more of exudate absorption, retention, or the like) while balancing cost savings from minimizing usage of particulate material. For example, using the Retention Capacity Value Method to determine a Retention Capacity Value (RCV) and the Cradle Intake Test Method to measure a first intake value, and with the particulate material basis weight values noted above, the absorbent article 1000 can include a ratio of a RCV to a first intake value of between about 5 g / s and 11 g / s, such as between about 6 g / s and 10 g / s, such as between about 7 g / s and 9 g / s, or about 8 g / s. These values can be achieved where a total RCV of the article is between about 375 g and about 410 g. As such, the absorbent article 1000 can provide an improved performance compared to conventional absorbent articles while minimizing the usage of particulate material.

[0154] The Cradle Intake Test Method that can be used to measure the first intake value parameter is described in PCT Patent Application Publication WO2023 / 113783, titled “Absorbent articles with low void volume”, which is hereby incorporated by reference in its entirety. Specifically, the Cradle Intake Test Method is performed on whole products. The Cradle Intake Test Method utilizes a test cradle apparatus simulating the body curvature of a child. ThePATENT109296-1411378-65084693PCT01 apparatus consists of a plexiglass box having a width of 33 cm, height of 19 cm, and a length of 30.5 cm. The box has a first internal plexiglass wall extending from a top front edge of the box downward toward the bottom of the box and toward a transverse centerline of the box. The first internal wall extends at an angle of approximately 60 degrees from horizontal. The apparatus consists of a second internal plexiglass wall extending from a top back edge of the box downward toward the bottom of the box and toward the transverse centerline of the box. The second internal wall also extends at an angle of approximately 60 degrees from horizontal. The first internal wall and the second internal wall meet at the bottom of the box proximate the transverse centerline of the box and form a rounded connection having a radius of curvature of approximately 3.8 cm - thereby simulating the body curvature of a child. A slot having a length of 6.5 mm is positioned at the bottom of the box and forms a separation between the first internal wall and the second internal wall. A tray may be placed under the plexiglass box to capture runoff fluid that enters the slot. The first and second internal walls extend substantially from a first side edge of the box to a second side edge of the box.

[0155] For each single sample, the sample is opened to a flat (side seams are severed if relevant) and stretched-out configuration and a center of the product is marked - utilizing a ruler or other measuring device to find the center. Next, an insult point is marked. For a size 4 diaper or diaper pant, the insult point is marked as 8.5 cm forward (toward a front of the article) from the marked center.

[0156] Prior to being placed within the cradle, the sample product is weighed to the nearest 0.1 g using a suitable measurement device - for example an electro-balance readable to 0.01 g. If the product includes containment flaps, the flaps should be slightly lifted from the liner by running a finger underneath the containment flaps to ensure that no portion of the flaps are adhered to the liner.

[0157] The product is placed in the cradle positioned such that the longitudinal center of the product is located at the transverse centerline of the box with the liner facing up. The product is adhered to the first and second internal walls with tape (including double sided tape) to ensure the sample lays flat against eh internal walls. An end of a clear tubing - such as Masterflex clear tubing L / S 16, having an exit diameter of approximately 3 mm - is positioned approximately 1PATENT109296-1411378-65084693PCT01 cm away from the marked target insult location, with the tubing end pointing directly at the target insult location.

[0158] The clear tubing is connected to a suitable pump apparatus that is capable of controlling a flow rate (for example, a Cole-Parmer peristaltic pump P / N 07551-20, with pump head P / N 77201-60). The pump is connected to a reservoir containing a saline solution (0.9 ± 0.0005% (w / w) aqueous isotonic saline) heated to 37 ± 1 degree C.

[0159] For a size 4 product, the total volume per insult is 85 ml, and the fluid is delivered at a rate of 15 ml / s. Accordingly, the pump is set to appropriately control to these parameters. Utilizing a stopwatch, an insult is timed, beginning when fluid contacts the sample. The timer is stopped once all of the insulted liquid has penetrated below the surface of the sample, and the time is recorded to the nearest 0.01 seconds. Failures can occur whereby more than a few drops of liquid migrate to non-ab sorptive portions of the sample, where the liquid runs into the cradle (for example, by leaking from the sample), and whereby fluid pools for longer than 5 minutes. These failures should be noted and the data not included in the reported results. The recorded time is the First Cradle Intake Time.

[0160] The measurements of this test method should be performed on samples conditioned at 23°C and 50% relative humidity. Additionally, for first cradle intake time measurement, at least four (4) samples should be tested, and the results averaged to obtain the first cradle intake time measurement.

[0161] The Retention Capacity Value Method that can be utilized to determine the RCV is an equation which comprises multiplying the sum of the Centrifuge Retention Capacity (CRC) value of the superabsorbent particulate material within the article and the value 3 by the amount, in grams, of the superabsorbent particulate material within the article. The CRC value of the particulate material is determined according to the EDANA recommended test method No. NWSP 241.0.R2 (15) "Determination of the Fluid Retention Capacity in Saline Solution by Gravimetric Measurement Following Centrifugation." Expressed as an equation, the Retention Capacity Value (RCV) is:RCV = (CRC value [of the superabsorbent particulate material] + 3) * Total mass of superabsorbent particulate material in the article (g)PATENT109296-1411378-65084693PCT01

[0162] With respect to FIGS. 10A, 10B, the first and second absorbent layers 1020, 1022 are described and depicted such that the second absorbent layer 1022 is disposed closer to the second cover 1040, which may be a bodyside liner. Although this is a preferred embodiment, it is believed that positioning the second absorbent layer 1022 (e.g., the absorbent layer comprised of portions 1021, 1023, 1025, 1027 of different and / or varying particulate material basis weights) closer to the first cover 1038 (e.g., an outer cover) will result in a similar or acceptable performance. Accordingly, such embodiments should be understood to be within the scope of this disclosure. Additionally, with respect to other FIGS., such as FIGS. 11-13, the absorbent layers may be positioned vertically in the Z-direction within absorbent article 1000 in either orientation as just described with respect to absorbent core 101 of FIGS. 10A, 10B.Example of Absorbent Cores with Cross-Direction Zoning

[0163] In one example, FIG. 11 depicts a top view of a non-limiting example of an absorbent core 1101 having some or all of the same features as prior embodiments of absorbent cores without departing from the claimed disclosure. The absorbent core 1101 may be depicted without a second material layer and an adhesive layer (e.g., the second material layer 1024 and adhesive layer 1026, as shown in FIG. 10B) to more clearly show the pattern of the absorbent layers 1020, 1122.

[0164] The longitudinal edges of the first material layer 1003 (e.g., the outer-most edges of the first material layer 1003 extending along the X-axis) and the second material layer may define the longitudinal edges of the absorbent core 1101. Although the longitudinal edges of the first material layer 1003 are depicted as extending past the longitudinal edges of the absorbent layers 1020, 1022 along a Y-axis, in other embodiments, the longitudinal edges of the first and / or second material layer may be aligned with the longitudinal edges of the first and / or second absorbent layers.

[0165] The second absorbent layer 1122 may include a first absorbent portion 1122a, a second absorbent portion 1122b, and a third absorbent portion 1122c. The absorbent portions 1122a, 1122c may be positioned adjacent the longitudinal edge of the underlying first absorbent layer 1020. The absorbent portions 1122a, 1122b, 1122c may each have a similar width along the Y- axis, however, in other embodiments, one or more of the absorbent portions may have a differentPATENT109296-1411378-65084693PCT01 width from each other. The absorbent portions 1122a, 1122b, 1122c may be laterally displaced from each other along the Y-axis on the first absorbent layer 1020. For example, the longitudinal edges of the absorbent portions 1122a, 1122c may be aligned with the longitudinal edges of the absorbent layer 1020. However, in other embodiments, the longitudinal edges of the one or more of the first absorbent layer and / or the first and / or third absorbent portions may be aligned with the longitudinal edges of the absorbent core (e.g., aligned with the longitudinal edges of one or both of the material layers). The second absorbent portion 1122b may overlap with a central longitudinal axis of the absorbent core 1101. However, in other embodiments, the second absorbent portion may be laterally offset from the central axis of the absorbent core (e.g., positioned closer to one of the first or third absorbent portions).

[0166] The first absorbent portion 1122a and the second absorbent portion 1122b may define a first gap 1129a therebetween. The second absorbent portion 1122b and the third absorbent portion 1122c may define a second gap 1129b therebetween. For example, the absorbent portions 1122a, 1122b, 1122c may be spaced from each other such that the gaps 1129a, 1129b may be between about 1% and 40% of a total width of the absorbent core 1101 (e.g., along the Y-axis), such as between about 3% and 30%, such as between about 7% and 23%, such as between about 9% and 21%, such as between about 11% and 19%, such as between about 13% and 17%, or about 15%. The absorbent portions 1122a, 1122b, 1122c may be spaced equidistant from each other such that the gaps 1129a, 1129b may be substantially similar in size. However, in other embodiments, the absorbent portions may not be spaced equidistant from each other such the first gap and the second gap may be different in size. In other embodiments, there may be more or fewer than three absorbent portions, such as two, four, five, or the like. As will be discussed further below, the position and dimensions of the absorbent portions 1122a, 1122b, 1122c relative to the first absorbent layer 1020 may provide certain exudate retention and absorption benefits.

[0167] The absorbent portions 1122a, 1122b, 1122c may each include a length along the X- axis that is substantially similar to a length of the first absorbent layer 1020 along the X-axis. In other embodiments, one or more of the absorbent portions may have a different length than each other. For example, one absorbent portion may have a greater or lesser length than another absorbent portion. Additionally, the top longitudinal edge of the first absorbent portion 1122aPATENT109296-1411378-65084693PCT01 along the Y-axis may align with a top longitudinal edge of the first absorbent layer 1020 and the bottom longitudinal edge of the third absorbent portion 1122c may align with the bottom longitudinal edge of the first absorbent layer 1020. This may be beneficial to ensure that exudate does not leak past any portion of the lateral edges of the absorbent core 1101. However, in other embodiments, one or more of the first and third absorbent portions may be offset from the longitudinal edges of the first absorbent layer.

[0168] The absorbent layers 1020, 1122 may include a different surface area (e.g., along a X-Y plane) from each other. For example, the second absorbent layer 1122 may include a lesser surface area than the first absorbent layer 1020. The surface area of the second absorbent layer 1122 may be between about 50% and 90% of the first absorbent layer 1020, such as between about 55% and 85%, or between about 60% and 85%, or between about 65% and 80%.

[0169] In particular embodiments, it may be important to ensure that a portion of the second absorbent layer 1122 is disposed along the longitudinal centerline of the absorbent core 1101 (e.g., such as the second absorbent portion 1122b positioned along the X-direction centerline). This ensures that a portion of the absorbent core 1101 having a greater basis weight (e.g., due to including both the second layer 1122 and the first layer 1020) is aligned with typical insult points of the absorbent core 1101. It is desirable, from an intake and leakage standpoint, to ensure that a width of a portion of the second layer 1122 (such as the second absorbent portion 1122b) has a width in the Y-direction of between about 40% and about 65% of a total Y-direction width of the core 1101, such as between about 40% and about 60%, such as between about 40% and about 55%, or such as between about 40% and about 50%. In such embodiments, the centered portion of the second layer 1122 (e.g., the second absorbent portion 1122b) may have a greater Y- direction extent than other portions of the second layer 1122 (e.g., the absorbent portions 1122a, 1122c). For example, the non-centered absorbent portions 1122a, 1122c may each have Y- direction extents of between about 10% and about 20% of a total Y-direction width of the core 1101, such as between about 10% and about 17.5%, or such as between about 10% and about 15%.

[0170] The absorbent portions 1122a, 1122b, 1122c may include a substantially similar basis weight as each other. For example, the absorbent portions 1122a, 1122b, 1122c may each includePATENT109296-1411378-65084693PCT01 a basis weight that is within about a 20% deviation of each other, such as about a 10% deviation, such as about a 5% deviation, or being completely the same. The second absorbent layer 1122 may include a different basis weight of particulate material compared to the first absorbent layer 1020 (e.g., as a result of the gaps 1129a, 1129b). For example, the second absorbent layer 1122 may include between a first particulate material basis weight of between about 40% and 80% of a second particulate material basis weight of the first absorbent layer 1020, such as between about 50% and 70%, or about 60%. However, in other embodiments, the second absorbent layer can have a lesser and / or substantially similar (e.g., substantially equal) particulate material basis weight as the first absorbent layer (e.g., where the first absorbent layer has a greater thickness and / or concentration of particulate material than the second absorbent layer).

[0171] In a similar manner as to that described above with respect to FIGS. 10A, 10B including the absorbent layers 1020, 1022 and the absorbent core 1000, according to some embodiments such as that of FIG. 11, the adhesive may be disposed in a relatively uniform manner throughout the absorbent layers 1020, 1122 of the absorbent core 1101. For example, even while the systems of the disclosure are configured to provide the gaps 1129a, 1129b in the second absorbent layer 1122, the application of the adhesive may not be configured to be dispersed only in those regions of the absorbent layers 1020, 1122 which include particulate material. Rather, in at least some embodiments, the adhesive is disposed in a relatively uniform manner throughout the absorbent layers 1020, 1122 such that the adhesive has a variance of less than about 15% of an average adhesive basis weight of the absorbent layers 1020, 1122, by less than about 10%, by less than about 5%, or may not vary at all. Accordingly, with respect to, for example, the second absorbent layer 1122 of FIG. 11, the adhesive may have a relatively uniform basis weight throughout the second absorbent layer 1122 while the particulate material may be distributed in different portions such that the basis weight of the particulate material of the second absorbent layer 1122 varies throughout the second absorbent layer 1122.Example of Absorbent Cores with Cross-Direction Zoning & Machine Direction Zoning

[0172] In other embodiments, the absorbent portions may not have a length similar to a length of the first absorbent layer. For example, FIG. 12 depicts a non-limiting example of an absorbent core 1201 having some or all of the same features as prior embodiments of absorbent coresPATENT109296-1411378-65084693PCT01 without departing from the claimed disclosure. The absorbent core 1201 may be depicted without a second material layer and an adhesive layer to more clearly show the pattern of the absorbent layers 1020, 1222.

[0173] The absorbent portions 1222a, 1222b, 1222c may have a longitudinal length along the X-axis that is less than a longitudinal length of the first absorbent layer 1020 such that the lateral edges of the absorbent portions 1222a, 1222b, 1222c may be offset from the lateral edges of the first absorbent layer 1020. As in other embodiments with respect to other FIGs., such as FIG. 10B, it may be important to ensure that a location and X-direction length of the portions 1222a, 1222b, 1222c of the absorbent layer 1222 are similar to the location and X-direction length of the body portion 1023. The lateral edges of the absorbent portions 1222a, 1222b, 1222c can have particulate material basis weight slopes similar to the slopes of the transition portions 1021, 1025, 1027, shown in FIG. 10B. For example, the right-most lateral edges of the absorbent portions 1222a, 1222b, 1222c can include particulate material basis weight slopes corresponding to the second transition portion 1025 while the left-most lateral edges of the absorbent portions 1222a, 1222b, 1222c can include particulate material basis weight slopes corresponding to the transition portions 1021, 1027. In some embodiments, one or more of the absorbent portions may have a different length than each other. However, in other embodiments, the lateral edges of the absorbent portions may be aligned with the lateral edges of the first absorbent layer. Each of the absorbent portions 1222a, 1222b, 1222c may be equally offset from the lateral edges of the first absorbent layer 1020. However, in other embodiments, one or more off the absorbent portions may be offset a different distance from the lateral edges of the first absorbent layer than the other.

[0174] The relative dimension and position of the absorbent portions 1222a, 1222b, 1222c relative to the first absorbent layer 1020 may be beneficial to provide optimal exudate absorption and retention while minimizing costs. For example, the absorbent portions 1222a, 1222b, 1222c may be positioned along a central portion and longitudinal edges of the absorbent core 1201 to optimally absorb and retain exudate. At the same time, the absorbent portions 1222a, 1222b, 1222c may be sized to minimize the use of particulate material and save costs. Accordingly, the absorbent core 1201 may provide improved performance and decreased costs compared to conventional absorbent cores.PATENT109296-1411378-65084693PCT01

[0175] In a similar manner as to that described above with respect to FIGS. 10 A, 10B including the absorbent layers 1020, 1022 and the absorbent core 1000, according to some embodiments such as that of FIG. 12, the adhesive may be disposed in a relatively uniform manner throughout the absorbent layers 1020, 1222 of the absorbent core 1201. For example, even while the systems of the disclosure are configured to provide the portions 1222a, 1222b, 1222c in the absorbent layer 1222 as shown in FIG. 12, the application of the adhesive may not be configured to be dispersed only in those portions 1222a, 1222b, 1222c which include particulate material. Rather, in at least some embodiments, the adhesive is disposed in a relatively uniform manner throughout the absorbent layers 1020, 1222 such that the adhesive has a variance of less than about 15% of an average adhesive basis weight of the absorbent layers 1020, 1222, by less than about 10%, by less than about 5%, or may not vary at all. Accordingly, with respect to, for example, the second absorbent layer 1222 of FIG. 12, the adhesive may have a relatively uniform basis weight throughout the second absorbent layer 1222 while the particulate material may be distributed in the different portions 1222a, 1222b, 1222c such that the basis weight of the particulate material of the absorbent layer 1222 varies throughout the absorbent layer 1222.Example of Absorbent Cores with Machine Direction Zoning

[0176] In some embodiments, the second absorbent layer may not include a plurality of absorbent portions. For example, FIG. 13 depicts a non-limiting example of an absorbent core 1301 having some or all of the same features as prior embodiments of absorbent cores without departing from the claimed disclosure. The absorbent core 1301 may be depicted without a second material layer and an adhesive layer to more clearly show the pattern of the absorbent layers 1020, 1322.

[0177] The second absorbent layer 1322 may be a continuous layer of particulate material overlay ed over a portion of the first absorbent layer 1020. The second absorbent layer 1322 may include a width along the Y-axis that is substantially similar to a width of the first absorbent layer 1020. However, in other embodiments, the second absorbent layer may have a different width than the first absorbent layer. Additionally, the lateral edges of the second absorbent layer 1322 are offset (e.g., along the X-axis) from the lateral edges of the first absorbent layer 1020.PATENT109296-1411378-65084693PCT01As in other embodiments with respect to other FIGs., such as FIG. 10B, it may be important to ensure that a location and X-direction length of the second layer 1322 is similar to the location and X-direction length of the body portion 1023. However, in other embodiments, one or both of the lateral edges of the second absorbent layer may be aligned with the respective lateral edges of the first absorbent layer. The right-most lateral edge of the second absorbent layer 1322 can include particulate material basis weight slopes corresponding to the second transition portion 1025 (as shown in FIG. 10B) while the left-most lateral edges of the second absorbent layer 1322 can include particulate material basis weight slopes corresponding to the transition portions 1021, 1027.

[0178] The dimension and position of the second absorbent layer 1322 relative to the first absorbent layer 1020 may be beneficial to provide improved exudate absorption and retention. For example, the larger surface concentration of particulate material at the second absorbent layer 1322 may maximize exudate retention and absorption in this area as it may be determined that the area of the absorbent core 1301 occupied by the second absorbent layer 1322 may be particularly likely to receive exudate. As such, the absorbent core 1301 may provide improved exudate absorption and retention compared to conventional absorbent cores.

[0179] In a similar manner as to that described above with respect to FIGS. 10A, 10B including the absorbent layers 1020, 1022 and the absorbent core 1000, according to some embodiments such as that of FIG. 13, the adhesive may be disposed in a relatively uniform manner throughout the absorbent layers 1020, 1322 of the absorbent core 1301. For example, even while the systems of the disclosure are configured to provide the second absorbent layer 1322 as having an X-direction extent less than the first absorbent layer 1020 as shown in FIG.13, the application of the adhesive may not be configured to be dispersed only in the portions of the absorbent core 1301 which include particulate material. Rather, in at least some embodiments, the adhesive is disposed in a relatively uniform manner throughout the absorbent layers 1020, 1322 such that the adhesive has a variance of less than about 15% of an average adhesive basis weight of the absorbent layers 1020, 1322, by less than about 10%, by less than about 5%, or may not vary at all. Accordingly, with respect to, for example, the absorbent layers 1020, 1322 of FIG. 13, the adhesive may have a relatively uniform basis weight throughout the absorbent layers 1020, 1322 while the particulate material may be distributed in the differentPATENT109296-1411378-65084693PCT01 absorbent layers 1020, 1322 such that the basis weight of the particulate material of the absorbent layers 1020, 1322 varies throughout one or more of the absorbent layers 1020, 1322.Example of Absorbent Cores with Particulate Material Free Regions

[0180] In other embodiments, both the first and second absorbent layers may define gaps free of particulate material. For example, FIG. 14 depicts a non-limiting example of an absorbent core 1401 having some or all of the same features as prior embodiments of absorbent cores without departing from the claimed disclosure. The absorbent core 1401 may be depicted without a second material layer and an adhesive layer to more clearly show the pattern of the first absorbent layer (not shown in FIG. 14) and the second absorbent layer 1422.

[0181] Although not shown, the first absorbent layer may be positioned between the second absorbent layer 1422 and the first material layer 1003 to underly the second absorbent layer 1422. The second absorbent layer 1422 may define a first gap 1429a and a second gap 1429b free of particulate material. The first absorbent layer (e.g., the first absorbent layer 1030, as shown in FIG. 10B) may also define gaps free of particulate material. The gaps of the first absorbent layer may be aligned with the gaps 1429a, 1429b such that the gaps 1429a, 1429b of the second absorbent layer 1422 and the gaps of the first absorbent layer may be spaces free of particulate material along the absorbent core 1401. In other words, the gaps 1429a, 1429b of the second absorbent layer 1422 and the gaps of the first absorbent layer may expose the first material layer 1003 to other layers positioned atop the second absorbent layer 1422 (e.g., the adhesive layer 1026 and the second material layer 1024, as shown in FIG. 10B). In some embodiments, where the absorbent core 1401 includes intervening layers between the first absorbent layer and the second absorbent layer 1422 (e.g., a resilient layer 1030, as shown in FIG. 10B), this intervening layer may also define gaps aligned with the gaps 1429a, 1429b such that the first material layer 1003 is exposed through those intervening layers.

[0182] The second absorbent layer 1422 and the underlying first absorbent layer may define particulate material basis weight slopes leading into and out of the gaps 1429a, 1429b. For example, the second absorbent layer 1422 and the underlying first absorbent layer may define a first particulate material basis weight slope decreasing at the left-most lateral edge of the gaps 1429a, 1429b along the X-axis extending in a right-ward direction that is double the particulatePATENT109296-1411378-65084693PCT01 material basis weight slope of the second transition portion 1025, as shown in FIG. 10B. For example, this first particulate material basis weight slope may be between about -0.8 gsm / mm and -26 gsm / mm, such as between about -1 gsm / mm and -11 gsm / mm, such as between about - 1.2 gsm / mm and -18 gsm / mm, such as between about -1.4 gsm / mm and -14 gsm / mm, such as between about -1.6 gsm / mm and -1. gsm / mm, such as between about -1.8 gsm / mm and -6 gsm / mm, or about -4 gsm / mm. Additionally, a second particulate material basis weight slope increasing at the right-most lateral edge of the gaps 1429a, 1429b along the X-axis extending in a right-ward direction that is double the particulate material basis weight slope of the third transition portion 1027, as shown in FIG. 10B. For example, this second particulate material basis weight slope may be between about 1 gsm / mm and 20 gsm / mm, such as between about 1.5 gsm / mm and 16 gsm / mm, such as between about 2 gsm / mm and 12 gsm / mm, such as between about 3 gsm / mm and 8 gsm / mm, such as between about 4 gsm / mm or 7 gsm / mm, or about 6 gsm / mm. However, in other embodiments, the second absorbent layer may be the only absorbent layer in the absorbent core. In this example, the first particulate material basis weight slope may be similar to the particulate material basis weight slope of the second transition portion, as shown in FIG. 10B, and the second particulate material basis weight slope may be similar to the particulate material basis weight slope of the first transition portion, as shown in FIG. 10B.

[0183] Although the respective gaps of the first absorbent layer and the gaps 1429a, 1429b of the second absorbent layer 1422 are depicted as being aligned, in other embodiments, the gaps may be offset from each other. Additionally, the gaps of the first absorbent layer and the gaps 1429a, 1429b of the second absorbent layer 1422 may have a substantially similar size. However, in other embodiments, the gaps of the respective absorbent layers may have a different size (e.g., the gaps of the first absorbent layer may have a different size than the gaps of the second absorbent layer). Even further, each of the gaps along each absorbent layer may be a different size (e.g., each gap along one absorbent layer is a different size than the other gaps of the same absorbent layer). Even further, each of the absorbent layers may have more or fewer than two gaps, such as one, three, four, five, or the like. In yet other embodiments, the first absorbent layer may have no gaps such that the gaps defined in the second absorbent layer exposes the first absorbent layer.PATENT109296-1411378-65084693PCT01

[0184] The gaps 1429a, 1429b of the second absorbent layer 1422 and the gaps of the first absorbent layer may be beneficial to minimize particulate material usage while still providing good exudate absorption and retention. For example, it may be determined that no particulate material is required along gaps 1429a, 1429b in order to optimize exudate absorption and retention. As such, material costs may be minimized by providing particulate material along the absorbent core 1401 except for the gaps 1429a, 1429b.

[0185] In a similar manner as to that described above with respect to FIGS. 10A, 10B including the absorbent layers 1020, 1022 and the absorbent core 1000, according to some embodiments such as that of FIG. 14, the adhesive may be disposed in a relatively uniform manner throughout the second absorbent layer 1422 of the core absorbent 1401. For example, even while the systems of the disclosure are configured to provide the portions 1429a, 1429b in the second absorbent layer 1422 as shown in FIG. 14, the application of the adhesive may not be configured to be dispersed only in those portions of the second absorbent layer 1422 which include particulate material. Rather, in at least some embodiments, the adhesive is disposed in a relatively uniform manner throughout the second absorbent layer 1422 such that the adhesive has a variance of less than about 15% of an average adhesive basis weight of the absorbent layers 1020, 1222, by less than about 10%, by less than about 5%, or may not vary at all. Accordingly, with respect to, for example, second absorbent layer 1422 of FIG. 14, the adhesive may have a relatively uniform basis weight throughout the second absorbent layer 1422 while the particulate material may be distributed in the second absorbent layer 1422 such that the basis weight of the particulate material of the second absorbent layer 1422 varies throughout the second absorbent layer 1422.Examples of Absorbent Cores with Patterns to Accommodate Leg Cutouts

[0186] In yet other embodiments, the second absorbent layer may have an irregular shape. For example, FIG. 15 depicts a non-limiting example of an absorbent core 1501 having some or all of the same features as prior embodiments of absorbent cores without departing from the claimed disclosure. The absorbent core 1501 may be depicted without a second material layer and an adhesive layer to more clearly show the pattern of the absorbent stack 1522. The absorbent stack 1522 may correspond to a stack of absorbent layers (e.g., the absorbent layers 1020, 1022, asPATENT109296-1411378-65084693PCT01 shown in FIG. 10B). The absorbent stack 1522 may include two or more absorbent layers, as described above, however, in other embodiments, the absorbent stack may only include one absorbent layer. In some embodiments, one or more additional layers may be positioned between the absorbent layers of the absorbent stack 1522 (e.g., the resilient layer 1030, as shown in FIG. 10B). Each of the layers of the absorbent stack 1522 may include a substantially similar shape / pattern (e g., as defined by the outer perimeter corresponding to the outer-most edges of the absorbent stack 1522 along the X-Y plane, as shown in FIG. 15 and as described below). However, in other embodiments, the underlying layers below the absorbent layer may include a different shape / pattern than the second absorbent layer.

[0187] The absorbent stack 1522 may include multiple absorbent regions that each have different dimensions, as visually depicted by dashed-lines. For example, the absorbent stack 1522 may include a central region 1507 aligned with a longitudinal central axis (e.g., along the X-axis) of the absorbent core 1501. In other embodiments, the central region may be offset and / or transverse to the longitudinal central axis of the absorbent core. The absorbent stack 1522 may include a first inner side region 1502a, a second inner side region 1502b, a third inner side region 1504a, and a fourth inner side region 1504b extending laterally away from the central region 1507. The absorbent stack 1522 may include a first outer side region 1503a extending laterally away from the first inner side region 1502a, a second outer side region 1503b extending laterally away from the second inner side region 1502b, a third outer side region 1504a extending laterally away from the third inner side region 1504a, and a fourth outer side region 1505a extending laterally away from the fourth inner side region 1504b. In this manner, the side regions 1502a, 1502b, 1503a, 1503b, 1504a, 1504b, 1505a, 1505b may be considered side regions that extend laterally away from the central region 1507.

[0188] As shown, the absorbent stack 1522 may define gaps between certain regions corresponding to portions of streams of particulate materials that were diverted by eductor systems during formation, as described above. For example, the inner-most lateral edges of the outer side regions 1503a, 1505a may define a first gap 1529a therebetween, the inner-most lateral edges of the inner side regions 1502a, 1504a may define a second gap 1531a therebetween, the inner-most lateral edges of the outer side regions 1503b, 1505b may define a third gap 1529b therebetween, and the inner-most lateral edges of the inner side regions 1502b,PATENT109296-1411378-65084693PCT011504b may define a fourth gap 1531b therebetween. These gaps 1529a, 1529b, 1531a, 1531b may correspond to regions of the absorbent core 1501 that include substantially no particulate material as a result of being formed by the absorbent article formation system 100. For example, the outer side regions 1503a, 1505a may correspond to, with reference to FIG. 1, uninterrupted portions of the second stream 117b of particulate material from a common channel (or multiple adjacent common channels) of the second deposition chute 140b and the first gap 1529a may correspond to interrupted portions of that stream diverted by the second eductor system 160a. The outer side regions 1503b, 1505b may correspond to uninterrupted portions of the second stream 117b of particulate material from a common channel (or multiple adjacent common channels) of the second deposition chute 140b and the third gap 1529b may correspond to interrupted portions of that stream diverted by the second eductor system 160b. The inner side regions 1502a, 1504a may correspond to uninterrupted portions of the second stream 117b of particulate material from a common channel (or multiple adjacent common channels) of the second deposition chute 140b and the second gap 1531a may correspond to interrupted portions of that stream diverted by the second eductor system 160b. The inner side regions 1502b, 1504b may correspond to uninterrupted portions of the second stream 117b of particulate material from a common channel (or multiple adjacent common channels) of the second deposition chute 140b and the fourth gap 1531b may correspond to interrupted portions of that stream diverted by the second eductor system 160b. The central region 1507 may correspond to a steady and uninterrupted portion of the second stream 117b free of interruptions by the second eductor system 160b. The regions 1502a, 1502b, 1503a, 1503b, 1504a, 1504b, 1505a, 1505b, 1507 can be contiguous such that the second absorbent layer 1022 may be free of interruptions along its surface area along the X-Y plane other than the gaps 1529a, 1529b, 1531, 1531b formed by second the eductor system 160b.

[0189] As noted above, adhesive may be distributed substantially uniformly throughout the absorbent core 1501. In some embodiments, an adhesive layer (e.g., the adhesive layer 1026, as shown in FIG. 10B) may be positioned in the gaps 1529a, 1529b, 1531a, 1531b. Accordingly, the adhesive may be disposed in a relatively uniform manner throughout the absorbent core 1501. For example, even while the systems of the disclosure are configured to provide the gaps 1529a, 1529b, 1531a, 1531b, as shown in FIG. 15, the application of the adhesive may not bePATENT109296-1411378-65084693PCT01 configured to be dispersed only in those portions of the absorbent core 1501 which include particulate material. Rather, in at least some embodiments, the adhesive is disposed in a relatively uniform manner throughout the absorbent core 1501 such that the adhesive has a variance of less than about 15% of an average adhesive basis weight of the core 1501, by less than about 10%, by less than about 5%, or may not vary at all, even while the basis weight of the particulate material varies throughout the core 1501.

[0190] Such an adhesive layer present in gaps 1529a, 1529b, 1531a, 1531b can help ensure efficient removal of waste if the material in the gaps 1529a, 1529b, 1531a, 1531b is trimmed. For example, the adhesive can help to maintain the trimmed waste pieces together for easier and efficient removal and processing. Accordingly, the absorbent article formation system 100 can form the absorbent core 1501 to include the pattern of regions 1502a, 1502b, 1503a, 1503b, 1504a, 1504b, 1505a, 1505b, 1507 and gaps 1529a, 1529b, 1531a, 1531b, as shown.

[0191] The absorbent stack 1522 may define particulate material basis weight slopes along the lateral ends of the absorbent stack 1522 and any underlaying absorbent layers. For example, the left-most lateral ends of the regions 1502a, 1502b, 1503a, 1503b, 1504a, 1504b, 1505a, 1505b, 1507 may include a first increasing particulate material basis weight slope, in a first direction from the first lateral absorbent edge 1521, of between about 4.75 gsm / mm and 30 gsm / mm, such as between about 5.75 gsm / mm and 25 gsm / mm, such as between about 6.75 gsm / mm and 20 gsm / mm, such as between about 7.75 gsm / mm and 15 gsm / mm, such as between about 8.75 gsm / mm and 10 gsm / mm, or the like. The right-most lateral ends of the regions 1502a, 1502b, 1503a, 1503b, 1504a, 1504b, 1505a, 1505b, 1507 may include a second decreasing particulate material basis weight slope, along the first direction from the first lateral absorbent edge 1521, of between about -4.75 gsm / mm and -30 gsm / mm, such as between about -5.75 gsm / mm and -25 gsm / mm, such as between about -6.75 gsm / mm and -20 gsm / mm, such as between about -7.75 gsm / mm and -15 gsm / mm, such as between about -8.75 gsm / mm and -10 gsm / mm, or the like.

[0192] In some embodiments, the absorbent article 1501 may be configured such that the left portions of the absorbent article 1501 may interface with a front waist of a user and the right portions of the absorbent article 1501 may interface with a rear waist of the user. In this manner, the side regions 1502a, 1502b, 1503a, 1503b can be front side regions while the side regionsPATENT109296-1411378-65084693PCT011504a, 1504b, 1505a, 1505b can be rear side regions. However, in other embodiments, the interface orientation may be reversed such that the right side regions may be the front side regions and the left side regions may be the rear side regions.

[0193] The central region 1507 and side regions 1502a, 1502b, 1503a, 1503b can each include a left-most lateral edge aligned with each other that, collectively, defines a first lateral absorbent edge 1521 of the absorbent stack 1522. The central region 1507 and side regions 1504a, 1504b, 1505a, 1505b can each include a right-most lateral edge aligned with each other that, collectively, defines a second lateral absorbent edge 1523 of the absorbent stack 1522. However, in other embodiments, less than all of the right-most and / or left-most lateral edges of the various absorbent portions may be aligned with each other.

[0194] One or more of the regions 1502a, 1502b, 1503a, 1503b, 1504a, 1504b, 1505a, 1505b, 1507 may include varying dimensions relative to each other. For example, the central region 1507 can include a greater width than each of the side regions 1502a, 1502b, 1503a, 1503b, 1504a, 1504b, 1505a, 1505b. However, in other embodiments, the central region can include a substantially similar width to one or more of the side regions. The central region 1507 can include a greater length than each of the side regions 1502a, 1502b, 1503a, 1503b, 1504a, 1504b, 1505a, 1505b. However, in other embodiments, the central region can include a substantially similar length to one or more of the side regions. The side regions 1502a, 1502b, 1503a, 1503b, 1504a, 1504b, 1505a, 1505b may each include a substantially similar width. However, in other embodiments, one or more of the side regions may include a different width than at least one of the other side regions. The inner side regions 1502a, 1502b can include a greater length than the outer side regions 1503a, 1503b. The outer side regions 1503a, 1503b can include a greater length than the inner side regions 1504a, 1504b. The inner side regions 1504a, 1504b can include a greater length than the outer side regions 1505a, 1505b. However, in other embodiments, each of the side regions can include any length relative to each other.

[0195] The maximum and minimum dimensions of the combined regions 1502a, 1502b, 1503a, 1503b, 1504a, 1504b, 1505a, 1505b, 1507 may correspond with maximum and minimum dimensions of the absorbent stack 1522. For example, the maximum width of the absorbent stack 1522 may be defined between the outer-most longitudinal edges of the regions 1502a, 1502b,PATENT109296-1411378-65084693PCT011503a, 1503b, 1504a, 1504b, 1505a, 1505b. The minimum width of the absorbent stack 1522 may be defined between the outer-most longitudinal edges of the central region 1507. The maximum length of the absorbent stack 1522 may be defined between the outer-most lateral edges of the regions 1502a, 1502b, 1503a, 1503b, 1504a, 1504b, 1505a, 1505b. The minimum length of the absorbent stack 1522 may be defined between inner-most lateral edges of the regions 1505a, 1505b. However, in other embodiments, the maximum and minimum dimensions of the second absorbent layer may change corresponding to different lengths and widths of the absorbent portions. The maximum length of the absorbent core 101 may be between about 100 mm and 700 mm, such as between about 200 mm and 600 mm, such as between about 300 mm and 500 mm, or about 400 mm. The maximum width of the absorbent core 101 can be greater than about 80 mm, such as greater than about 90 mm, such as greater than about 100 mm, such as greater than about 110 mm, such as greater than about 120 mm, such as greater than about 130 mm, such as greater than about 140 mm, such as greater than about 150 mm, such as greater than about 160 mm, or such as greater than about 170 mm.

[0196] The side regions 1502a, 1502b, 1503a, 1503b (e.g., the front side regions) can include a length between one of the outer-most lateral edges of the side regions 1502a, 1502b or outermost lateral edges of the side regions 1503a, 1503b that is between about 25% and 65% of the maximum length of the second absorbent layer 1022, such as between about 30% and 60%, such as between about 35% and 55%, such as between about 40% and 50%, or about 45%. The side regions 1504a, 1504b, 1505a, 1505b (e.g., the rear side regions) can include a length between the outer-most lateral edges of the side regions 1504a, 1504b or outer-most lateral edges of the side regions 1505a, 1505b that is between about 5% and 25% of the maximum length of the second absorbent layer 1022, such as between about 10% and 20%, or about 15%.

[0197] The regions 1502a, 1502b, 1503a, 1503b, 1504a, 1504b, 1505a, 1505b, 1507 can account for a different portion of the total particulate material for the absorbent layer 1022. For example, the central region 1507 can account for between about 55% and 95% (by weight) of a total amount of particulate material of the absorbent core 101, such as between about 65% and 85%, or about 75%. The side regions 1502a, 1502b, 1503a, 1503b (e.g., the front side regions) can account for between about 5% and 35% (by weight) of a total amount of particulate material of the absorbent core 101, such as between about 10% and 35%, such as between about 15% andPATENT109296-1411378-65084693PCT0125%, or about 20%. The side regions 1504a, 1504b, 1505a, 1505b (e.g., the rear side regions) can account for between about 2% and 12% (by weight) of a total amount of particulate material of the absorbent core 101, such as between about 3% and 10%, such as between about 4% and 8%, such as between about 5% and 6%, or the like.

[0198] The front side regions 1502a, 1502b, 1503a, 1503b can include a greater average particulate material basis weight than the central region 1507. Similarly, the rear side regions 1504a, 1504b, 1505a, 1505b can include a greater average particulate material basis weight than the central region 1507. However, in other embodiments, the central region can include a greater average particulate material basis weight than one or more of the front side regions or the rear side regions. In yet other embodiments, the central region can include a substantially similar average particulate material basis weight than the front side regions ore the rear side regions.

[0199] As noted above, the absorbent article formation system 100 can form absorbent cores having any desired patterned shape, including patterned shapes other than the pattern shown in the absorbent core 1501. For example, FIG. 16 depicts an absorbent core 1601 including all of the features of the absorbent core 1501 except as noted below. In particular, the second absorbent layer 1622 can include a first side region 1602a, a second side region 1602b, a third side region 1604a, and a fourth side region 1604b extending laterally away from the central region 1607. The side regions 1602a, 1602b may include a first length similar to the outer side regions 1503a, 1503b, as shown in FIG. 15, and the side regions 1604a, 1604b may include a second length similar to the outer side regions 1505a, 1505b, as shown in FIG. 15. However, in other embodiments, the first and second side regions may include any lengths. The side regions 1602a, 1602b may each include a first width corresponding to the combined widths of the respective side regions 1502a, 1502b, 1503a, 1503b, as shown in FIG. 15, and the side regions 1604a, 1604b may each include a second width corresponding to the combined widths of the respective side regions 1503a, 1503b, 1505a, 1505b, as shown in FIG. 15. However, in other embodiments, the side regions may include any width. These relative dimensions of the side regions 1604a, 1604b may provide good exudate absorption and retention while minimizing particulate material (e.g. SAM) usage.PATENT109296-1411378-65084693PCT01

[0200] In yet other embodiments, the absorbent core may include less side regions. For example, FIG. 17 depicts an absorbent core 1701 similar to the absorbent core 1601 except the absorbent core 1701 may not include the rear side regions (e.g., the side regions 1604a, 1604b). This may further save on particulate material usage as it may be determined that a greater amount of particulate material may be required along the front of the absorbent core 1701.

[0201] In another embodiment, the absorbent core may include inner and outer front side regions having varying lengths. For example, FIG. 18 depicts an absorbent core 1801 similar to the absorbent core 1601 except as noted below. In particular, the second absorbent layer 1822 may not include rear side regions (e.g., the side regions 1604a, 1604b). Additionally, the second absorbent layer 1822 may include a first inner side region 1802a and a second inner side region 1802b extending laterally away from the central region 1807. The second absorbent layer 1822 may include a first outer side region 1803a extending laterally away from the first inner side region 1802a, a second outer side region 1803b extending laterally away from the second inner side region 1802b. The side regions 1802a, 1802b, 1803a, 1803b may include similar dimensions as the outer side regions 1502a, 1502b, 1503a, 1503b, as shown in FIG. 15, except that the inner side regions 1802a, 1802b may include a length that is greater than the inner side regions 1502a, 1502b by between about 15% and 55% of a length of the inner side regions 1502a, 1502b, such as between about 20% and about 50%, such as between about 25% and about 45%, or such as between about 30% and about 45%. This increased length may provide greater exudate absorption and retention.

[0202] FIG. 19 depicts an example flowchart showing a process 1900 for forming an absorbent article using an absorbent article formation system 100, as shown in FIG. 1. The below operation of the components of the absorbent article formation system 100 can be performed by a computer system 2210, such as the computer system depicted in FIG. 22.

[0203] Box 1910 may include supplying particulate material from a reservoir, through a channel defined between a first chute wall and a second chute wall of a chute opposite the first chute wall, to an outlet defined at an end region of the chute. With reference to FIGS. 8 A and 8B, the particulate material may be supplied through one or more (e.g., all) of the deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g from the chute inlets 841a, 841b, 841c, 841d,PATENT109296-1411378-65084693PCT01841e, 841 f, 841g defined at the first end 850 of the first deposition chute 840a to the chute outlets 842a, 842b, 842c, 842d, 842e, 842f, 842g defined at the second end 851 of the first deposition chute 840a. For example, with reference to FIG. 9 A, an uninterrupted particulate stream 919 may flow from the first particulate material reservoir 113a in the first deposition channel 845a to the first chute outlet 842a.

[0204] The channel may be defined between a first chute wall and a second chute wall opposite the first side wall. With reference to FIGS. 8A and 8B, each of the deposition channels 845a, 845b, 845c, 845d, 845e, 845f, 845g may be correspondingly defined between the channel walls 847a, 847b, 847c, 847d, 847e, 847f, 847g, 847h. The side walls 846, 856 may define, therebetween, an eductor opening 843 sized and shaped to receive a portion of an eductor system (e.g., a mixed fluid component 364 of a first eductor system 160a, as shown in FIGS. 3A and 3B). The side walls 848, 858 may define, therebetween, a return opening 244 sized and shaped to receive a return chute (e g., a return chute 115a, as shown in FIGS. 9A and 9B).

[0205] The first chute wall defines a first opening and the second chute wall defines a second opening. For example, the side walls 846, 856 and channel walls 847a, 847b, 847c, 847d, 847e, 847f, 847g, 847h may define interruption window 857a, 857b, 857c, 857d, 857e, 857f, 857g that are each in fluid communication with a corresponding deposition channel 845a, 845b, 845c, 845d, 845e, 845f, 845g. The interruption window 857a, 857b, 857c, 857d, 857e, 857f, 857g may be sized and shaped to receive a mixed fluid to interrupt a stream of particulate material flowing within a corresponding deposition channel 845a, 845b, 845c, 845d, 845e, 845f, 845g. The side walls 848, 858 and channel walls 847a, 847b, 847c, 847d, 847e, 847f, 847g, 847h may define bypass windows 844a, 844b, 844c, 844d, 844e, 844f, 844g that are each in fluid communication with a corresponding deposition channel 845a, 845b, 845c, 845d, 845e, 845f, 845g such that an interrupted portion of a stream of particulate material may be received from the deposition channel 845a, 845b, 845c, 845d, 845e, 845f, 845g into a corresponding bypass window 844a, 844b, 844c, 844d, 844e, 844f, 844g.

[0206] Box 1920 may include flowing, by actuating a valve, a pressurized fluid through the first opening, the channel, and the second opening along a first flow path. For example, with reference to FIG. 9B, the control valves 791, 793 may be actuated to release motive fluids 923,PATENT109296-1411378-65084693PCT01928 into the valve channels 781, 783 and draw in ambient fluid 922 into the suction channel 761. The motive fluids 923, 928 and ambient fluid 922 may mix together in the mixed fluid channel 763 to form a mixed fluid 902 that exits the mixed fluid component 364 with a fully developed velocity profile. The mixed fluid 902 may flow from the first mixed fluid outlet 667a, through the first interruption window 857a, and into the first deposition channel 845a along a mixed fluid flow path B.

[0207] The first flow path intersects the particulate material flowing within the channel such that a first interrupted portion of the particulate material is redirected by the pressurized fluid from the channel into the second opening and a first uninterrupted portion of the particulate material within the channel exits the chute through the outlet. For example, with continued reference to FIG. 9B, the mixed fluid 902 may flow along the mixed fluid flow path B to intersect the deposition flow path A of the uninterrupted particulate stream 919 such that the mixed fluid 902 forces the interrupted portion 921 from the first deposition 945a into the first bypass window 844a. The uninterrupted particulate portions 916, 917, 918 may exit the first deposition chute 140a to be deposited on a substrate (e.g., the first substrate layer 103 or the first absorbent layer 120a, as shown in FIG. 1, or the resilient layer 1030, as shown in FIG. 10B).

[0208] The mixed fluid 902 may be released for a desired period of time according to a desired length of gaps 924, 925 between the uninterrupted particulate portions 916, 917, 918. For example, releasing the mixed fluid 902 for a longer time may result in the gap being larger (e.g., the second gap 925) whereas releasing the mixed fluid 902 for a shorter time may result in the gap being smaller (e.g., the first gap 924). In this manner, an absorbent core may be formed with a desired gap length along a lengthwise direction (e.g., the X-direction, as shown in the absorbent cores 101, 1101, 1201, 1301, 1401, 1501, 1601, 1701, 1801 of FIGS. 10B-18) A similar process may be performed for each of the other deposition channels 845b, 845c, 845d, 845e, 845f, 845g of the deposition chute 140a, as seen in FIGS. 8A and 8B. In this manner, an absorbent core may be formed with a desired gap pattern along a width-wise direction (e.g., the Y-direction, as shown in the absorbent cores 1101, 1201, 1301, 1401, 1501, 1601, 1701, 1801 of FIGS. 11-18). Accordingly, with reference to FIG. 1, a first absorbent layer 120a may be formed having a desired pattern along a length and width of a first substrate layer 103. Subsequent layers may be positioned on the first substrate layer 103 (e.g., a second absorbent layer 120b, a resilientPATENT109296-1411378-65084693PCT01 layer, a second substrate layer 124, or the like) and additionally processing steps may be performed on the first absorbent layer 120a (e.g., pressing by a nip station 127, cutting by a cutting station 129, or the like).

[0209] In some embodiments, after the uninterrupted particulate portions 916, 917, 918 are deposited and absorbent cores are formed, with reference to FIG. 1, a weight sensor or basis weight sensor may determine a position of the absorbent layers 120a, 120b on the first substrate layer 103 or intervening layer for further processing. For example, the computer system may determine a cutting location of the absorbent layers 120a, 120b by using sensor data (e.g., the weight distribution profile) to identify locations along the first substrate layer 103 or second substrate layer 124 with lesser amounts of particulate materials. In one example, the computer system may perform such a process to cut the absorbent layers 120a, 120b to form the absorbent core 101 depicted in FIG. 10B. Specifically, the computer system may send instructions to cut the absorbent layers 120a, 120b 103, 124 at locations corresponding to the transition ends 1060, 1070 to form the absorbent core 101 shown in FIG. 10B. In some embodiments where the absorbent layers 120a, 120b include gap regions disposed proximate side edges of the absorbent core 101, the absorbent core 101 - and more specifically the first substrate layer 103, the second substrate layer 124, and any adhesive in the regions - may be cut such that the absorbent core 101 has cut-edges and non-cut edges, where the cut-edges are located with the gap region(s) of the absorbent core 101.

[0210] In other embodiments, the computer system may determine whether the absorbent layers 120a, 120b are properly positioned (e.g., properly centered) on the belt system 114. Based on whether one or more of the particulate material weight distribution profile, particulate material basis weight profile, or particulate material density profile meets a threshold standard, the production process may be adjusted. For example, after the computer system determines that one or more of the particulate material weight distribution profile, particulate material basis weight profile, or particulate material density profile does not meet a threshold standard, the computer system may adjust a cutting location of the absorbent layers 120a, 120b. The cutting station 129 may cut the absorbent layers 120a, 120b according to these cutting locations to form an absorbent core 101.PATENT109296-1411378-65084693PCT01

[0211] FIG. 20 depicts an example flowchart showing a process 1700 for using eductor systems 160a, 160b, as shown in FIG. 1. The below operation of the components of the eductor systems 160a, 160b can be performed by a computer system, such as the computer system 2210 depicted in FIG. 22.

[0212] Box 2010 may include providing a particulate material deposition system. For example, with reference to FIGS. 9A and 9B, a first particulate material deposition system 130a may be provided. The particulate material deposition system may comprise a chute defining a first opening and a second opening opposite the first opening. For example, the first particulate material deposition system 130a may include a first deposition chute 140a defining a first interruption window 857a and a first bypass window 844a. The particulate material deposition system may also comprise an eductor system having a first and second motive fluid channel, a suction fluid channel, a mixed fluid channel, and an exit port. For example, the first eductor system 160a may include motive fluid channels 596a, 598a, a suction channel 761, a mixed fluid channel 763, and a first mixed fluid outlet 667a.

[0213] Box 2020 may include supplying the absorbent material from a reservoir through the chute. For example, an uninterrupted particulate stream 919 may be supplied from the first particulate material reservoir 113a may supply through the first deposition chute 140a.

[0214] Box 2030 may include flowing, by actuating a first control valve, a first fluid from a fluid source into the first motive fluid channel. For example, the first control valve 791 may release a first motive fluid 923 into the first motive fluid channel 596a through the first valve channel 781. The second control valve 793 may release a second motive fluid 928 into the second motive fluid channel 598a through the second valve channel 783. The control valves 791, 793 may release the motive fluids 923, 928 with a pressure of between about 0.7 bar and 9 bar. In some embodiments, the first control value 791 and the second control valve 793 may be actuated at different times. Such a control scheme where the first control value 791 and the second control valve 793 are actuated at different times may allow the systems 160a, 160b to form absorbent portion(s) on a substrate having different lengths.

[0215] Flowing the first fluid into the first and second motive fluid channels may draw in a second fluid into the suction fluid channel such that the first fluid and the second fluid mixesPATENT109296-1411378-65084693PCT01 together to form a mixed fluid in the mixed fluid channel that exits the mixed fluid outlet into the first opening of the chute and contacts the particulate material in the chute. For example, when the motive fluids 923, 928 move past the first suction outlet 470a, the motive fluids 923, 928 may create a pressure differential that draws in an ambient fluid 922 into the suction channel 761. The motive fluids 923, 928 and the ambient fluid 922 may flow into the mixed fluid channel 762 to intermix and form a mixed fluid 902. The mixed fluid 902 may exit the first mixed fluid outlet 667a with a fully developed velocity profile. As noted above, the fully developed velocity profile may minimize the risk that the mixed fluid 902 disrupts the uninterrupted portions 916, 917, 918 and, therefore, allows for the uninterrupted portions 916, 917, 918 to be deposited on an initial material layer with gaps that are freer of particulate material (e.g., to reduce material waste) and allows for a more consistent thickness of the deposited uninterrupted portions 916, 917, 918.

[0216] FIG. 21 depicts an example flowchart showing a process 2100 for forming an absorbent article using an absorbent article formation system 100, as shown in FIG. 1. The below operation of the components of the eductor systems 160a, 160b can be performed by a computer system, such as the computer system 2210 depicted in FIG. 22.

[0217] Box 2110 may include moving a substrate in a machine direction. For example, with reference to FIG. 1, a first substrate layer 103 may be moved on a belt system 114 in a machine direction 104 (e.g., along an X-axis). In other embodiments, the substrate may include the first absorbent layer 120a or the resilient layer (e.g., the resilient layer 1030, as shown in FIG. 10B) being moved in the machine direction 104.

[0218] Box 2120 may include metering a first flow of absorbent material toward the substrate through a deposition chute. For example, with reference to FIG. 9A, the uninterrupted particulate stream 919 may be metered from the first particulate material reservoir 113a toward a substrate (e.g., the first substrate layer 103, as shown in FIG. 1) through the first deposition chute 140a.

[0219] Box 2130 may include interrupting the first flow of absorbent material with an air mass to move a first portion of the first flow of absorbent material from the deposition chute to an alternate chute such that a remaining flow of absorbent material exits the deposition chute. For example, with reference to FIG. 9B, the mixed fluid 902 may interrupt the interrupted particulatePATENT109296-1411378-65084693PCT01 portion 921 to move the interrupted particulate portion 921 from the first deposition chute 140a to the return chute 115a, resulting in the uninterrupted particulate portions 916, 917, 918 exiting the first deposition chute 140a.

[0220] Box 2140 may include applying an adhesive to the remaining flow of absorbent material exiting the deposition chute. For example, with reference to FIG. 1, the adhesive applicators 107a, 109a may apply adhesives 108a, 110a on the first stream 117a of particulate material exiting the first deposition chute 140a or the adhesive applicators 107b, 109b may apply adhesives 108b, 110b on the second stream 117b of particulate material exiting the second deposition chute 140b.

[0221] Box 2150 may include forming an absorbent layer on the substrate with the remaining flow of absorbent material that has exited the deposition chute and contacted the substrate. For example, the uninterrupted particulate portions 916, 917, 918 that has exited the deposition chutes 140a, 140b may contact the first substrate layer 103, the first absorbent layer 120a, or a resilient layer may form an absorbent layer (e.g., the first absorbent layer 120a or the second absorbent layer 120b, as shown in FIG. 1). Subsequent layers may be positioned on the absorbent layers (e.g., a second absorbent layer 120b, a resilient layer, a second substrate layer 124, or the like) and additionally processing steps may be performed on the first absorbent layer 120a (e.g., pressing by a nip station 127, cutting by a cutting station 129, or the like) to form the absorbent core 101.

[0222] The absorbent layer comprises the remaining flow of absorbent material extending along the substrate to define a body portion and a transition portion extending from the body portion to a region of the substrate without absorbent material. For example, with reference to FIG. 10B, the second absorbent layer 1022 may include the remaining flow of absorbent material that exited the deposition chute (e.g., the deposited portions of the interrupted particulate portions 916, 917, 918, as shown in FIG. 9B). The second absorbent layer 1022 may include a body portion 1023 and transition portions 1021, 1025 extending from the body portion 1023, and a third transition portion 1027 spaced from the second transition portion 1022 by a gap 1029. As noted above, each of the transition portions 1021, 1025, 1027 may have a particular material basis weight slope corresponding to resulting from an optimized deposition of particulatePATENT109296-1411378-65084693PCT01 material (e.g., maximizing absorbent article performance while minimizing particulate material usage) formed by the particulate material deposition systems described above (e.g., the particulate material deposition systems 130a, 130b, as shown in FIG. 1).

[0223] Any of the computer systems mentioned herein may utilize any suitable number of subsystems. Examples of such subsystems are shown in FIG. 22 in computer system 2210. In some embodiments, a computer system includes a single computer apparatus, where the subsystems can be the components of the computer apparatus. In other embodiments, a computer system can include multiple computer apparatuses, each being a subsystem, with internal components. A computer system can include desktop and laptop computers, tablets, mobile phones and other mobile devices.

[0224] The subsystems shown in FIG. 22 are interconnected via a system bus 2275. Additional subsystems such as a printer 2274, keyboard 2278, storage device(s) 2279, monitor 2276 (e.g., a display screen, such as an LED), which is coupled to display adapter 2282, and others are shown. Peripherals and input / output (I / O) devices, which couple to EO controller 2271, can be connected to the computer system by any number of means known in the art such as input / output (EO) port 2277 (e.g., USB, FireWire®). For example, I / O port 2277 or external interface 2281 (e.g., Ethernet, Wi-Fi, etc.) can be used to connect computer system 2210 to a wide area network such as the Internet, a mouse input device, or a scanner. The interconnection via system bus 2275 allows the central processor 2273 to communicate with each subsystem and to control the execution of a plurality of instructions from system memory 2272 or the storage device(s) 2279 (e.g., a fixed disk, such as a hard drive, or optical disk), as well as the exchange of information between subsystems. The system memory 2272 and / or the storage device(s) 2279 may embody a computer readable medium. Another subsystem is a data collection device 2285, such as a camera, microphone, accelerometer, and the like. Any of the data mentioned herein can be output from one component to another component and can be output to the user.

[0225] A computer system can include a plurality of the same components or subsystems, e.g., connected together by external interface 2281, by an internal interface, or via removable storage devices that can be connected and removed from one component to another component. In some embodiments, computer systems, subsystem, or apparatuses can communicate over a network. InPATENT109296-1411378-65084693PCT01 such instances, one computer can be considered a client and another computer a server, where each can be part of a same computer system. A client and a server can each include multiple systems, subsystems, or components.

[0226] Aspects of embodiments can be implemented in the form of control logic using hardware circuitry (e.g., an application specific integrated circuit or field programmable gate array) and / or using computer software stored in a memory with a generally programmable processor in a modular or integrated manner, and thus a processor can include memory storing software instructions that configure hardware circuitry, as well as an FPGA with configuration instructions or an ASIC. As used herein, a processor can include a single-core processor, multicore processor on a same integrated chip, or multiple processing units on a single circuit board or networked, as well as dedicated hardware. Based on the disclosure and teachings provided herein, a person of ordinary skill in the art will know and appreciate other ways and / or methods to implement embodiments of the present disclosure using hardware and a combination of hardware and software.

[0227] Any of the software components or functions described in this applications may be implemented as software code to be executed by a processor using any suitable computer language such as, for example, Java, C, C++, C#, Objective-C, Swift, or scripting language such as Perl or Python using, for example, conventional or object-oriented techniques. The software code may be stored as a series of instructions or commands on a computer readable medium for storage and / or transmission. A suitable non-transitory computer readable medium can include random access memory (RAM), a read only memory (ROM), a magnetic medium such as a harddrive or a floppy disk, or an optical medium such as a compact disk (CD) or DVD (digital versatile disk) or Blu-ray disk, flash memory, and the like. The computer readable medium may be any combination of such devices. In addition, the order of operations may be re-arranged. A process can be terminated when its operations are completed, but could have additional steps not included in a figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination may correspond to a return of the function to the calling function or the main function.PATENT109296-1411378-65084693PCT01

[0228] Such programs may also be encoded and transmitted using carrier signals adapted for transmission via wired, optical, and / or wireless networks conforming to a variety of protocols, including the Internet. As such, a computer readable medium may be created using a data signal encoded with such programs. Computer readable media encoded with the program code may be packaged with a compatible device or provided separately from other devices (e.g., via Internet download). Any such computer readable medium may reside on or within a single computer product (e.g., a hard drive, a CD, or an entire computer system), and may be present on or within different computer products within a system or network. A computer system may include a monitor, printer, or other suitable display for providing any of the results mentioned herein to a user.

[0229] Any of the methods described herein may be totally or partially performed with a computer system including one or more processors, which can be configured to perform the steps. Any operations performed with a processor (e.g., aligning, determining, comparing, computing, calculating) may be performed in real-time. The term ^real-time" may refer to computing operations or processes that are completed within a certain time constraint. The time constraint may be 1 minute, 1 hour, 1 day, or 7 days. Thus, embodiments can be directed to computer systems configured to perform the steps of any of the methods described herein, potentially with different components performing a respective step or a respective group of steps. Although presented as numbered steps, steps of methods herein can be performed at a same time or at different times or in a different order. Additionally, portions of these steps may be used with portions of other steps from other methods. Also, all or portions of a step may be optional. Additionally, any of the steps of any of the methods can be performed with modules, units, circuits, or other means of a system for performing these steps.

[0230] In some aspects, system, method, and apparatus for absorbent article formation systems are provided according to one or more of the following examples:

[0231] As used below, any reference to a series of examples is to be understood as a reference to each of those examples disjunctively (e.g., "Examples 1-4" is to be understood as "Examples 1, 2, 3, or 4").PATENT109296-1411378-65084693PCT01

[0232] Example l is a system comprising: a fluid source containing a pressurized fluid; a first valve in fluid communication with the fluid source, wherein the first valve is configured to control a release of the pressurized fluid; a reservoir containing a particulate material; and a chute comprising a first chute wall defining a first opening; and a second chute wall opposite the first chute wall, wherein: the second chute wall defines a second opening; the first chute wall and the second chute wall defines a first channel therebetween; the chute defines a first outlet; the first channel is in fluid communication with the reservoir and the first outlet; and a first flow path extends between the first valve and the second opening such that the first flow path extends through the first opening, the first channel, and the second opening.

[0233] Example 2 is the system of example 1, further comprising a return chute extending between the reservoir and the second opening, wherein an interior region of the return chute defines a second flow path extending between the reservoir and the second opening.

[0234] Example 3 is the system of any of examples 1 or 2, wherein a central line of the first flow path extending through a first central point of the first opening is offset from a second central point of the second opening.

[0235] Example 4 is the system of any of examples 1-3, further comprising a belt adjacent the first outlet and a basis weight sensor configured to receive data of an amount of particulate material positioned on the belt.

[0236] Example 5 is the system of any of examples 1-4, wherein the first valve includes a solenoid valve.

[0237] Example 6 is the system of example 5, wherein the solenoid valve includes an open position and a closed position; and the closed position is a default position of the solenoid valve.

[0238] Example 7 is the system of any of examples 1-6, further comprising a second valve in fluid communication with the fluid source, wherein: the chute defines a second outlet; the first chute wall and the second chute wall defines, therebetween, a second channel in fluid communication with the reservoir, the first opening, the second opening, and the second outlet; and a second flow path extending between the second valve and the second opening such that the second flow path extends through the first opening, the second channel, and the second opening.PATENT109296-1411378-65084693PCT01

[0239] Example 8 is the system of example 7, wherein the first flow path extends through the first channel but not the second channel and the second flow path extends through the second channel but not the first channel.

[0240] Example 9 is the system of any of examples 1-8, wherein the first flow path intersects the first channel at a point of intersection at an angle of between 60° and 120° relative to the first channel.

[0241] Example 10 is the system of any of examples 1-9, further comprising a non-transitory computer-readable medium encoding a set of computer-readable instructions, which, when executed on one or more processors on devices connected to a network: actuates the first valve from a closed position to an open position to release the pressurized fluid from the fluid source into the first flow path; and after sending the instructions, determines, using a sensor, if the first valve actuated from the closed position to the open position.

[0242] Example 11 is the system of example 10, wherein, when the non-transitory computer- readable medium determines that the first valve did not actuate from the closed position to the open position, the instructions further includes transmitting an alert indicating the first valve has failed.

[0243] Example 12 is the system of example 11, wherein the instructions further includes actuating a first auxiliary valve connected to the fluid source from a closed position to an open position to release the pressurized fluid from the fluid source into the first flow path.

[0244] Example 13 is the system of any of examples 1-12, wherein the first valve is configured to release the pressurized fluid at a pressure of between 0.5 bar and 8 bar.

[0245] Example 14 is the system of any of examples 1-13, further comprising an eductor component in fluid communication with the first valve, wherein the first flow path is further defined to extend from the first valve, through the eductor component, the first opening, the first channel, and the second opening.

[0246] Example 15 is the system of any of examples 1-14, wherein the first channel includes a first channel portion oriented in a first direction transverse to a gravitational axis and a second channel portion oriented in a second direction substantially aligned with the gravitational axis;PATENT109296-1411378-65084693PCT01 and the first opening and the second opening are between the first channel portion and the second channel portion.

[0247] Example 16 is the system of example 15, wherein the first direction is transverse to the gravitational axis between 30° and 60°.

[0248] Example 17 is a method of manufacturing a pulpless absorbent core comprising: supplying particulate material from a reservoir, through a channel defined between a first chute wall and a second chute wall of a chute opposite the first chute wall, to an outlet defined at an end region of the chute, wherein the first chute wall defines a first opening and the second chute wall defines a second opening; and flowing, by actuating a valve, a pressurized fluid through the first opening, the channel, and the second opening along a first flow path, wherein the first flow path intersects the particulate material flowing within the channel such that a first interrupted portion of the particulate material is redirected by the pressurized fluid from the channel into the second opening and a first uninterrupted portion of the particulate material within the channel exits the chute through the outlet.

[0249] Example 18 is the method of example 17, further comprising receiving the first interrupted portion of the particulate material in a return chute coupled to, and in fluid communication with, the second opening; and returning at least a portion of the first interrupted portion of the particulate material to a storage location.

[0250] Example 19 is the method of example 18, wherein the storage location includes the reservoir.

[0251] Example 20 is the method of any of examples 17-19, further comprising receiving, at a computer system from a basis weight sensor, basis weight data of the first uninterrupted portion of the particulate material deposited on a substrate material; and determining, using the computer system, a basis weight of the first uninterrupted portion of the particulate material deposited on the substrate material based at least in part on the basis weight data.

[0252] Example 21 is the method of example 20, further comprising determining, using the computer system, a position of the first uninterrupted portion of the particulate material relativePATENT109296-1411378-65084693PCT01 to the substrate material in a coordinate system based in part on the basis weight data and additional input data.

[0253] Example 22 is the method of example 21, wherein the additional input data includes at least one of a speed of movement of the substrate material relative to the chute, light contrast between different portions of the substrate material, physical measurements determined by a computer vision system between features of the substrate material or printed markers, or additional sensor data.

[0254] Example 23 is the method of any of examples 21 or 22, further comprising: determining, using the computer system, a cutting location to cut the substrate material relative to the first uninterrupted portion of the particulate material deposited onto the substrate material; and cutting the substrate material along the cutting location to form an absorbent core.

[0255] Example 24 is the method of any of examples 17-23, wherein the valve includes a solenoid valve.

[0256] Example 25 is the method of any of examples 17-24, further comprising flowing the pressurized fluid through the first opening, through a second channel defined between the first chute wall and the second chute wall, and through the second opening along a second flow path, wherein the second flow path intersects the particulate material flowing within the second channel such that a second interrupted portion of the particulate material flowing through the second channel is redirected by the pressurized fluid from the second channel into the second opening and a second uninterrupted portion of the particulate material within the second channel exits the chute through the outlet.

[0257] Example 26 is a system comprising a fluid source containing a pressurized fluid; a valve in fluid communication with the fluid source, wherein the valve is configured to control a release of the pressurized fluid; a reservoir containing a particulate material; a chute comprising: a first chute wall defining a first opening; a second chute wall opposite the first chute wall and defining a second opening; a first outlet; an interior region defining a first flow path extending between the reservoir to the first outlet; and an eductor system coupled to the chute, wherein: the eductor system defines a second flow path in fluid communication with the valve that extendsPATENT109296-1411378-65084693PCT01 between the valve, the first opening, and the second opening; and the second flow path intersects the first flow path.

[0258] In the foregoing specification, embodiments of the disclosure have been described with reference to numerous specific details that can vary from implementation to implementation. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. The sole and exclusive indicator of the scope of the disclosure, and what is intended by the applicants to be the scope of the disclosure, is the literal and equivalent scope of the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction. The specific details of particular embodiments can be combined in any suitable manner without departing from the spirit and scope of embodiments of the disclosure.

[0259] Additionally, spatially relative terms, such as "bottom” or "top" and the like can be used to describe an element and / or feature's relationship to another element(s) and / or feature(s) as, for example, illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use and / or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as a "bottom" surface can then be oriented "above" other elements or features. The device can be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0260] Terms “and,” “or,” and “an / or,” as used herein, may include a variety of meanings that also is expected to depend at least in part upon the context in which such terms are used. Typically, “or” if used to associate a list, such as A, B, or C, is intended to mean A, B, and C, here used in the inclusive sense, as well as A, B, or C, here used in the exclusive sense. In addition, the term “one or more” as used herein may be used to describe any feature, structure, or characteristic in the singular or may be used to describe some combination of features, structures, or characteristics. However, it should be noted that this is merely an illustrative example and claimed subject matter is not limited to this example. Furthermore, the term “at least one of’ if used to associate a list, such as A, B, or C, can be interpreted to mean any combination of A, B, and / or C, such as A, B, C, AB, AC, BC, AA, AAB, ABC, AABBCCC, etc.PATENT109296-1411378-65084693PCT01

[0261] Reference throughout this specification to “one example,” “an example,” “certain examples,” or “exemplary implementation” means that a particular feature, structure, or characteristic described in connection with the feature and / or example may be included in at least one feature and / or example of claimed subject matter. Thus, the appearances of the phrase “in one example,” “an example,” “in certain examples,” “in certain implementations,” or other like phrases in various places throughout this specification are not necessarily all referring to the same feature, example, and / or limitation. Furthermore, the particular features, structures, or characteristics may be combined in one or more examples and / or features.

[0262] In some implementations, operations or processing may involve physical manipulation of physical quantities. Typically, although not necessarily, such quantities may take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, or otherwise manipulated. It has proven convenient at times, principally for reasons of common usage, to refer to such signals as bits, data, values, elements, symbols, characters, terms, numbers, numerals, or the like. It should be understood, however, that all of these or similar terms are to be associated with appropriate physical quantities and are merely convenient labels. Unless specifically stated otherwise, as apparent from the discussion herein, it is appreciated that throughout this specification discussions utilizing terms such as “processing,” “computing,” “calculating,” “determining,” or the like refer to actions or processes of a specific apparatus, such as a special purpose computer, special purpose computing apparatus or a similar special purpose electronic computing device. In the context of this specification, therefore, a special purpose computer or a similar special purpose electronic computing device is capable of manipulating or transforming signals, typically represented as physical electronic or magnetic quantities within memories, registers, or other information storage devices, transmission devices, or display devices of the special purpose computer or similar special purpose electronic computing device.

[0263] In the preceding detailed description, numerous specific details have been set forth to provide a thorough understanding of claimed subject matter. However, it will be understood by those skilled in the art that claimed subject matter may be practiced without these specific details. In other instances, methods and apparatuses that would be known by one of ordinary skill have not been described in detail so as not to obscure claimed subject matter. Therefore, it isPATENT109296-1411378-65084693PCT01 intended that claimed subject matter not be limited to the particular examples disclosed, but that such claimed subject matter may also include all aspects falling within the scope of appended claims, and equivalents thereof.

Claims

WHAT IS CLAIMED IS:

1. A system comprising: a fluid source containing a pressurized fluid; a first valve in fluid communication with the fluid source, wherein the first valve is configured to control a release of the pressurized fluid; a reservoir containing a particulate material; and a chute comprising: a first chute wall defining a first opening; and a second chute wall opposite the first chute wall, wherein: the second chute wall defines a second opening; the first chute wall and the second chute wall defines a first channel therebetween; the chute defines a first outlet; the first channel is in fluid communication with the reservoir and the first outlet; and a first flow path extends between the first valve and the second opening such that the first flow path extends through the first opening, the first channel, and the second opening.

2. The system of claim 1, further comprising a return chute extending between the reservoir and the second opening, wherein an interior region of the return chute defines a second flow path extending between the reservoir and the second opening.

3. The system of claim 1, wherein a central line of the first flow path extending through a first central point of the first opening is offset from a second central point of the second opening.

4. The system of claim 1, further comprising a belt adjacent the first outlet and a basis weight sensor configured to receive data of an amount of particulate material positioned on the belt.

5. The system of claim 1, wherein the first valve includes a solenoid valve.

6. The system of claim 5, wherein: the solenoid valve includes an open position and a closed position; and the closed position is a default position of the solenoid valve.

7. The system of claim 1, further comprising a second valve in fluid communication with the fluid source, wherein: the chute defines a second outlet; the first chute wall and the second chute wall defines, therebetween, a second channel in fluid communication with the reservoir, the first opening, the second opening, and the second outlet; and a second flow path extending between the second valve and the second opening such that the second flow path extends through the first opening, the second channel, and the second opening.

8. The system of claim 7, wherein the first flow path extends through the first channel but not the second channel and the second flow path extends through the second channel but not the first channel.

9. The system of claim 1, wherein the first flow path intersects the first channel at a point of intersection at an angle of between 60° and 120° relative to the first channel.

10. The system of claim 1, further comprising a non-transitory computer-readable medium encoding a set of computer-readable instructions, which, when executed on one or more processors on devices connected to a network: actuates the first valve from a closed position to an open position to release the pressurized fluid from the fluid source into the first flow path; and after sending the instructions, determines, using a sensor, if the first valve actuated from the closed position to the open position.11 . The system of claim 10, wherein, when the non-transitory computer-readable medium determines that the first valve did not actuate from the closed position to the open position, the instructions further includes transmitting an alert indicating the first valve has failed.

12. The system of claim 11, wherein the instructions further includes actuating a first auxiliary valve connected to the fluid source from a closed position to an open position to release the pressurized fluid from the fluid source into the first flow path.

13. The system of claim 1, wherein the first valve is configured to release the pressurized fluid at a pressure of between 0.5 bar and 8 bar.

14. The system of claim 1, further comprising an eductor component in fluid communication with the first valve, wherein the first flow path is further defined to extend from the first valve, through the eductor component, the first opening, the first channel, and the second opening.

15. The system of claim 1, wherein: the first channel includes a first channel portion oriented in a first direction transverse to a gravitational axis and a second channel portion oriented in a second direction substantially aligned with the gravitational axis; and the first opening and the second opening are between the first channel portion and the second channel portion.

16. The system of claim 15, wherein the first direction is transverse to the gravitational axis between 30° and 60°.

17. A method of manufacturing a pulpless absorbent core comprising: supplying particulate material from a reservoir, through a channel defined between a first chute wall and a second chute wall of a chute opposite the first chute wall, to an outlet defined at an end region of the chute, wherein the first chute wall defines a first opening and the secondchute wall defines a second opening; and flowing, by actuating a valve, a pressurized fluid through the first opening, the channel, and the second opening along a first flow path, wherein the first flow path intersects the particulate material flowing within the channel such that a first interrupted portion of the particulate material is redirected by the pressurized fluid from the channel into the second opening and a first uninterrupted portion of the particulate material within the channel exits the chute through the outlet.

18. The method of claim 17, further comprising: receiving the first interrupted portion of the particulate material in a return chute coupled to, and in fluid communication with, the second opening; and returning at least a portion of the first interrupted portion of the particulate material to a storage location.

19. The method of claim 18, wherein the storage location includes the reservoir.

20. The method of claim 17, further comprising: receiving, at a computer system from a basis weight sensor, basis weight data of the first uninterrupted portion of the particulate material deposited on a substrate material; and determining, using the computer system, a basis weight of the first uninterrupted portion of the particulate material deposited on the substrate material based at least in part on the basis weight data.

21. The method of claim 20, further comprising determining, using the computer system, a position of the first uninterrupted portion of the particulate material relative to the substrate material in a coordinate system based in part on the basis weight data and additional input data.

22. The method of claim 21, wherein the additional input data includes at least one of a speed of movement of the substrate material relative to the chute, light contrast between different portions of the substrate material, physical measurements determined by a computervision system between features of the substrate material or printed markers, or additional sensor data.

23. The method of claim 21, further comprising: determining, using the computer system, a cutting location to cut the substrate material relative to the first uninterrupted portion of the particulate material deposited onto the substrate material; and cutting the substrate material along the cutting location to form an absorbent core.

24. The method of claim 17, wherein the valve includes a solenoid valve.

25. The method of claim 17, further comprising flowing the pressurized fluid through the first opening, through a second channel defined between the first chute wall and the second chute wall, and through the second opening along a second flow path, wherein the second flow path intersects the particulate material flowing within the second channel such that a second interrupted portion of the particulate material flowing through the second channel is redirected by the pressurized fluid from the second channel into the second opening and a second uninterrupted portion of the particulate material within the second channel exits the chute through the outlet.

26. A system comprising: a fluid source containing a pressurized fluid; a valve in fluid communication with the fluid source, wherein the valve is configured to control a release of the pressurized fluid; a reservoir containing a particulate material; a chute comprising: a first chute wall defining a first opening; a second chute wall opposite the first chute wall and defining a second opening; a first outlet; an interior region defining a first flow path extending between the reservoir to the first outlet; andan eductor system coupled to the chute, wherein: the eductor system defines a second flow path in fluid communication with the valve that extends between the valve, the first opening, and the second opening; and the second flow path intersects the first flow path.

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