The present invention relates to a method and apparatus for forming a composite structure, preferably for use in an absorbent structure used within the personal hygiene industry, such as for instance feminine hygiene garments, baby diapers and pants and adult incontinence garments. The present invention preferably provides a method and apparatus for depositing and positioning particulate materials in a desired pattern onto a moving carrier layer. The method allows accurate forming of a pattern of particulate material clusters at high production speed having improved attachment properties, with reduced raw material usage and relative low cost. The present invention foresees in the need for improved thin, flexible, lightweight absorbent structure having optimal absorption, distribution and retention.

A method for manufacturing an absorbent article, said method comprising guiding a first sheet material along a rotating member, wherein a surface of said rotating member is provided with a pattern with at least one suction zone and at least one non-suction zone; applying an absorbent material on said first sheet material on the rotating member; locally removing the absorbent material applied on at least one attachment portion of the first sheet material located above the at least one non-suction zone, such that at least one remaining portion of the first sheet material located above the at least one suction zone is covered with absorbent material and substantially no absorbent material is present on the at least one attachment portion; applying a second sheet material on top of the absorbent material on the first sheet material.

A process of making an absorbent article is disclosed. A liquid permeable topsheet web extending substantially continuously in a machine direction a backsheet web, and an intermediate layer are provided. The topsheet web has first and second surfaces. The backsheet web extends substantially continuously in the machine direction. The intermediate layer has a first and second surface. The topsheet and intermediate layer are aligned in a face to face relationship such that the second surface of the topsheet in in contact with the first surface of the intermediate layer and simultaneously mechanically deformed which combines the topsheet with the intermediate layer. The topsheet web and intermediate layer are nested together such that a majority of the three-dimensional protrusions formed in the topsheet web coincide with and fit together with a majority of the three-dimensional protrusions formed in the intermediate layer to provide a topsheet/intermediate layer laminate web having three-dimensional protrusions.

An absorbent core for an absorbent article, the absorbent core comprising at least two layers, each layer having a width w and a length l along a first plane and a thickness t extending perpendicular thereto, wherein the layers are arranged in facing relationship along the first plane, and wherein the layers comprise a polymeric foam having an open cell and interconnected porous structure. The first and second layers comprise an anisotropic cell structure having an axis of anisotropy extending substantially parallel to a longest length of a plurality of substantially neighbouring cells. The axis of anisotropy of the second layer extends substantially perpendicular to said thickness t and parallel to said first plane and the axis of anisotropy of the first layer is substantially perpendicular to the axis of anisotropy of the second layer.

An absorbent core includes a core wrap having a top layer and a bottom layer enclosing superabsorbent polymer. The absorbent core is substantially free of cellulose fibers. The absorbent layer comprises a non-rectangular central portion having a front edge, a back edge and two longitudinally-extending side edges. Each side edge defines a recess along a portion of its length; a first side portion present in one of the recess and a second side portion present in the other recess. The proximal edges of the side portions are convex; and either the distal edges of the side portions are concave so that the side portions are crescent-shaped; or the distal edges of the side portions is straight. The absorbent core further includes a first and second folding guide, and when the absorbent core is folded along the folding guides, the central portion and the side portions form a three-dimensional basin.

Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming a pulpless absorbent core may comprise moving a foraminous forming surface having un-masked portions and masked portions in a machine direction, the un-masked portions defining an absorbent core region. The method may further comprise depositing particulate material at a velocity of less than 1200 meters per minute in the absorbent core region while applying a vacuum. The absorbent core region may comprise: a front core region spanning a first half of the absorbent core region and a rear core region spanning a second half, wherein the front core region trails the rear core region in the machine direction, and the masked portions of the foraminous forming surface block airflow through the forming surface to cause greater than 60% of the particulate material deposited in the absorbent core region to locate in the front core region.

An absorbent article has an absorbent body obtained by mixing and accumulating fibers and high absorbent polymer particles. A wrapping sheet includes an intermediate part located on a front face side of the absorbent body and both side parts folded back to a back face side of the absorbent body from the intermediate part. Distal ends of the both side parts of the wrapping sheet are overlapped on the back face side of the absorbent body to form a connecting portion. A total weight of the high absorbent polymer particles is larger than a total weight of the fibers in the absorbent body. A content rate of the high absorbent polymer particles of the absorbent body increases stepwise or continuously from the back face side toward the front face side.

Applicants' invention includes a disposable absorbent article including a top sheet, an absorbent core, and a self-supporting fiberized web situated between the top sheet and the absorbent core, wherein the self-supporting fiberized web includes a hot melt composition and is free of absorbent materials.

Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming a pulpless absorbent core may comprise moving a foraminous forming surface having un-masked portions and masked portions in a machine direction, the un-masked portions defining an absorbent core region. The method may further comprise depositing particulate material at a velocity of less than 1200 meters per minute in the absorbent core region while applying a vacuum. The absorbent core region may comprise: a front core region spanning a first half of the absorbent core region and a rear core region spanning a second half, wherein the front core region trails the rear core region in the machine direction, and the masked portions of the foraminous forming surface block airflow through the forming surface to cause greater than 60% of the particulate material deposited in the absorbent core region to locate in the front core region.

Disclosed is an absorbent article comprising; (a) a topsheet having a skin facing side and a core facing side, the topsheet being liquid permeable and having the core facing side coated with at least about 0.01 mg/m.sup.2, preferably from about 0.05 mg/m.sup.2 to about 0.2 mg/m.sup.2, of calcium carbonate; (b) a backsheet which is liquid impermeable; and (c) an absorbent core comprising an absorbent material, the absorbent core disposed between the topsheet and the backsheet.