The present invention relates to an apparatus and a method of applying a single SAP (Super Adsorbent Polymer) type granules or multiple SAP types at high speed in a continuous or intermittent 2-dimensional or 3-dimensional profile via volumetric or gravimetric metering onto a receiving system such as a carrier layer and/or into an air stream for use in an absorbent article, particularly diapers for babies or adults, training pants, pull-up diapers (diaper pants), sanitary napkins, panty liners or the like. These articles typically comprise of a carrier layer with the SAP particles and/or a mixed SAP and fiber core together with further layers, making up the complete article.

A method for making a disposable absorbent core comprises depositing absorbent particulate polymer material from a plurality of reservoirs in a printing roll onto a substrate disposed on a grid of a support which includes a plurality of cross bars extending substantially parallel to and spaced from one another so as to form channels extending between the plurality of cross bars. The plurality of reservoirs in the first peripheral surface are arranged in an array comprising rows extending substantially parallel to and spaced from one another. A disposable absorbent article and apparatus for making an absorbent article are also disclosed.

An absorbent structure comprising a planar substrate, an auxiliary glue applied on the substrate, an absorbent material comprising from 80% to 100% by weight of superabsorbent particles deposited on the substrate on an absorbent material deposition area comprising a pattern of absorbent material land areas separated by absorbent material-free junction areas, wherein the deposition area can be notionally divided in eight deposition zones of equal length along the longitudinal direction. A fibrous thermoplastic adhesive layer immobilizes at least some of the absorbent material. The absorbent material is profiled along the longitudinal direction so that at least one of the eight deposition zones is a zone of lower absorbent material amount and the auxiliary glue is absent, or present at a level of at least 50% by weight lower than the average amount of auxiliary glue in at least one of these zones of lower absorbent material amount.

Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming an absorbent core may comprise moving a forming surface in a machine direction, creating a pressure differential across the forming surface, advancing a base carrier sheet on the forming surface in the machine direction, applying a first adhesive onto the base carrier sheet, and applying a first quantity of particulate material onto the first adhesive at a first cross-machine direction width. The method may further comprise depositing a matrix of material onto the first quantity of particulate material at a second cross-machine direction width, the matrix of material comprising a second quantity of particulate material and a second adhesive, wherein the second cross-machine direction width is smaller than the first cross-machine direction width, and wherein the second quantity of particulate material and the adhesive are pre-mixed prior to deposition onto the first quantity of particulate material.

A method is provided, for dissipating and entrapping super absorbent polymer particles (11, 12, 13, 14) within air-permeable, non-woven structures (100), for use in the construction of absorbent articles (600). The method comprises the steps of: (i) of constructing an air-permeable, non-woven structure (100) comprising at least first (1), second (2) and third (3) layers of non-woven fabric, each said layer having void spaces of differing size defined therein; (ii) dispersing absorbent particles (11, 12, 13, 4) onto an external surface (10) of the highest numbered layer of said air-permeable, non-woven structure (100) formed in step (i); and (iii) dissipating the dispersed absorbent particles (11, 12, 13, 14) within the air-permeable, non-woven structure (100) by applying an external energy source acting upon the absorbent particles (11, 12, 13, 14) in a direction substantially normal to the plane of the external surface (10) of the air-permeable, non-woven structure (100).

Disclosed is an absorbent core composite for a disposable absorbent article. The absorbent composite has a first fabric, a body side second fabric, and a plurality of aggregates of superabsorbent particles (SAP) situated between the first fabric second fabric. About each of a plurality of the SAP aggregates, an arrangement of spaced apart bond sites secures the second fabric to the first fabric and form a pocket in which the SAP aggregate is secured between the first fabric and the second fabric. The body side second fabric is a bulky nonwoven including fibers that entangle at least some particles in the SAP aggregate.

A forming pocket suitable for forming conglomerates from particulate material to be used as an absorbent padding for hygienic products, includes an external forming substrate for receiving particulate material, the substrate having openings and a shape conjugated to a form of the absorbent padding to be made. The forming pocket includes a grid supporting structure, which has openings and is coupleable with the substrate to support the substrate during suction of particulate material through the substrate. The supporting structure has an external surface configured to contact the substrate and has a shape conjugated to the shape of the substrate. A method of making the forming pocket includes obtaining from at least one first metal sheet first and second sets of elements having a plurality of cuts, and wedging the elements of the first set with the elements of the second set via the cuts to make the grid supporting structure.

An absorbent core for use in an absorbent article including a high loft central layer having deposited on two different surfaces thereon a first superabsorbent polymer SAP1 and a second superabsorbent polymer SAP2 in the form of particles that are at least partially distributed within the high loft layer. The SAP1 has a higher capacity than SAP2 and the permeability of SAP2 is more than 5×10-7 cm3.Math.s/g.

Disclosed is an absorbent core composite for a disposable absorbent article. The absorbent composite has a first fabric, a body side second fabric, and a plurality of aggregates of superabsorbent particles (SAP) situated between the first fabric second fabric. About each of a plurality of the SAP aggregates, an arrangement of spaced apart bond sites secure the second fabric to the first fabric and form a pocket in which the SAP aggregate is secured between the first fabric and the second fabric. The body side second fabric is a bulky nonwoven including fibers that entangle at least some particles in the SAP aggregate.

The present invention relates to a method of applying absorbent gelling material (AGM) granules by indirect printing onto an carrier layer for use in an absorbent article, particularly diaper for babies or adults, training pants, pull-up diapers (diaper pants), sanitary napkins, panty liners or the like. These articles typically comprise the carrier layer with the AGM particles together with further layers, making up the complete article.