Method And Apparatus For Making Disposable Absorbent Article With Absorbent Particulate Polymer Material And Article Made Therewith

• US 20100051166A1
• Filed: 08/03/2009
• Published: 03/04/2010
• Est. Priority Date: 08/26/2008
• Status: Active Grant

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Brandt Sanz, Miguel, Dziezok, Peter, Schmidt, Mattias, Beruda, Holger, Krause, Axel, Hundorf, Harald Hermann, Blessing, Horst, Stelzig, Lutz
• Granted Patent: US 8,206,533 B2
• Time in Patent Office: Days
• US Class Current: 156/62.800
• CPC Class Codes: A61F 13/15634 Making fibrous pads between sheets or webs
• CPC Class Codes: A61F 13/15658 Forming continuous, e.g. composite, fibrous webs, e.g. involving the application of pulverulent material on parts thereof
• CPC Class Codes: A61F 13/15699 Forming webs by bringing together several webs, e.g. by laminating or folding several webs, with or without additional treatment of the webs
• CPC Class Codes: A61F 13/5323 having absorbent material located in discrete regions, e.g. pockets
• CPC Class Codes: A61F 2013/530496 being fixed to fibres
• CPC Class Codes: A61F 2013/530554 and being fixed to a web
• CPC Class Codes: A61F 2013/530562 being arranged in discontinuous pattern
• CPC Class Codes: A61F 2013/53908 with adhesive
• CPC Class Codes: A61F 2013/53958 with separate adhesive layer
• CPC Class Codes: B05C 19/00 Apparatus specially adapted for applying particulate materials to surfaces
• CPC Class Codes: B32B 37/1207 Heat-activated adhesive B32B37/04 takes precedence
• CPC Class Codes: B32B 37/1284 Application of adhesive
• CPC Class Codes: B32B 37/24 with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• CPC Class Codes: B32B 38/1858 using vacuum
• CPC Class Codes: B32B 5/30 one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: Y10T 156/1007 Running or continuous length work

Abstract

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. The support and printing roll are arranged such that the plurality of cross bars are substantially parallel to the rows of the plurality of reservoirs and the absorbent particulate polymer material is deposited on the substrate in a pattern such that the absorbent particulate polymer material collects in rows on the first substrate formed between the first plurality of cross bars. A thermoplastic adhesive material is deposited on the absorbent particulate polymer material and the substrate to cover the absorbent particulate polymer material on the substrate and form an absorbent layer. A disposable absorbent article and apparatus for making an absorbent article are also disclosed.

Claims

1. A method of making a disposable absorbent article comprising:

providing a first support comprising a first grid including a first plurality of cross bars extending substantially parallel to and spaced from one another so as to form channels extending between the first plurality of cross bars;

providing a first printing roll having a first peripheral surface and a first plurality of reservoirs in the first peripheral surface arranged in an array comprising rows extending substantially parallel to and spaced from one another;

depositing absorbent particulate polymer material from the first plurality of reservoirs onto a first substrate disposed on the first grid, while the first support and first printing roll are arranged such that the first plurality of cross bars are substantially parallel to the rows of the first plurality of reservoirs, the absorbent particulate polymer material being deposited on the first substrate in a first pattern such that the absorbent particulate polymer material collects in rows on the first substrate formed between the first plurality of cross bars; and

depositing a thermoplastic adhesive material on the absorbent particulate polymer material and the first substrate to cover the absorbent particulate polymer material on the first substrate and form a first absorbent layer.

2. The method of claim 1 wherein:

the first grid of the first support extends in a machine direction and a cross direction substantially perpendicular to the machine direction and the first plurality of cross bars extend in the cross direction of the first grid and spaced from one another so that the channels extend between the first plurality of cross bars in the cross direction of the first grid;

the peripheral surface of the first printing roll extends in a machine direction and a cross direction substantially perpendicular to the machine direction, the rows of first plurality of reservoirs extend in the cross direction of the first peripheral surface and are spaced from one another in the machine direction of the first peripheral surface; and

the step of depositing comprises depositing the absorbent particulate polymer material from the first plurality of reservoirs onto the first substrate disposed on the first grid while the first support and first printing roll are arranged such that the machine direction of the first grid is substantially parallel to the machine direction of the first peripheral surface and the cross direction of the first grid is substantially parallel to the cross direction of the first peripheral surface.

3. The method of claim 1 further comprising:

providing a second support comprising a second grid including a second plurality of cross bars extending substantially parallel to and spaced from one another so as to form channels extending between the second plurality of cross bars;

providing a second printing roll having a second peripheral surface and a second plurality of reservoirs in the second peripheral surface arranged in an array comprising rows extending substantially parallel to and spaced from one another;

depositing absorbent particulate polymer material from the second plurality of reservoirs onto a second substrate disposed on the second grid, while the second support and second printing roll are arranged such that the second plurality of cross bars are substantially parallel to the rows of the second plurality of reservoirs, the absorbent particulate polymer material being deposited on the second substrate in a second pattern such that the absorbent particulate polymer material collects in rows on the second substrate formed between the second plurality of cross bars of the second support;

depositing a thermoplastic adhesive material on the absorbent particulate polymer material and the second substrate to cover the absorbent particulate polymer material on the second substrate and form a second absorbent layer;

combining said first and second absorbent layers together in juxtaposed relation such that at least a portion of said thermoplastic adhesive material of said first absorbent layer contacts at least a portion of the thermoplastic adhesive material of said second absorbent layer, the absorbent particulate polymer material is disposed between the first and second substrates in an absorbent particulate polymer material area, and the absorbent particulate polymer material is substantially continuously distributed across the absorbent particulate polymer material area.

4. The method of claim 3 wherein:

the first grid of the first support extends in a machine direction and a cross direction substantially perpendicular to the machine direction and the first plurality of cross bars extend in the cross direction of the first grid and spaced from one another so that the channels extend between the first plurality of cross bars in the cross direction of the first grid;

the second grid of the second support extends in a machine direction and a cross direction substantially perpendicular to the machine direction and the second plurality of cross bars extend in the cross direction of the second grid and spaced from one another so that the channels extend between the second plurality of cross bars in the cross direction of the second grid;

the peripheral surface of the first printing roll extends in a machine direction and a cross direction substantially perpendicular to the machine direction, the rows of first plurality of reservoirs extend in the cross direction of the first peripheral surface and are spaced from one another in the machine direction of the first peripheral surface;

the peripheral surface of the second printing roll extends in a machine direction and a cross direction substantially perpendicular to the machine direction, the rows of second plurality of reservoirs extend in the cross direction of the second peripheral surface and are spaced from one another in the machine direction of the second peripheral surface;

the step of depositing the absorbent particulate polymer material from the first plurality of reservoirs comprises depositing the absorbent particulate polymer material from the first plurality of reservoirs onto the first substrate disposed on the first grid while the first support and first printing roll are arranged such that the machine direction of the first grid is substantially parallel to the machine direction of the first peripheral surface and the cross direction of the first grid is substantially parallel to the cross direction of the first peripheral surface; and

the step of depositing the absorbent particulate polymer material from the second plurality of reservoirs comprises depositing the absorbent particulate polymer material from the second plurality of reservoirs onto the first substrate disposed on the second grid while the second support and second printing roll are arranged such that the machine direction of the second grid is substantially parallel to the machine direction of the second peripheral surface and the cross direction of the second grid is substantially parallel to the cross direction of the second peripheral surface.

5. The method claim 1, wherein the rows of absorbent particulate polymer material on the first substrate are separated by junction areas between the rows of absorbent particulate polymer material.

6. The method claim 3, wherein the rows of absorbent particulate polymer material on the first and second substrates are separated by junction areas between the rows of absorbent particulate polymer material and the step of combining comprises combining said first and second absorbent layers together so that the rows of absorbent particulate polymer material on the first substrate are disposed between and substantially parallel to rows of absorbent particulate polymer material on the second substrate.

7. The method claim 3, wherein the step of combining the first and second absorbent layers comprises combining the first and second absorbent layers together such that the first and second patterns of absorbent particulate polymer material are offset from one another in the machine direction.

8. The method claim 3, wherein:

the first support is a first support roll and the step of depositing the absorbent particulate polymer material on the first substrate further comprises depositing the absorbent particulate polymer material on the first substrate by rotating the first printing roll and rotating the first support roll; and

the second support is a second support roll and the step of depositing the absorbent particulate polymer material on the second substrate further comprises depositing the absorbent particulate polymer material on the second substrate by rotating the second printing roll and rotating the second support roll.

9. The method claim 8, wherein:

the first support roll is a first vacuum support roll and the step of depositing the absorbent particulate polymer material on the first substrate further comprises holding the first substrate to the first vacuum support roll with a vacuum; and

the second support roll is a second vacuum support roll and the step of depositing the absorbent particulate polymer material on the second substrate further comprises holding the second substrate to the second vacuum support roll with a vacuum.

10. The method claim 3, wherein the first and second plurality of reservoirs are cylindrical or conical.

11. The method claim 10, wherein the plurality of reservoirs in the first printing roll and the plurality of reservoirs each have a diameter of about 3 to about 8 mm, a spacing in a cross direction of about 5.5 to about 10 mm from reservoir center to reservoir center, and a spacing in a machine direction of about 8 to about 10 mm from reservoir center to reservoir center.

12. The method claim 1, wherein the first plurality of cross bars each have a substantially straight outwardly facing edge extending across substantially the entire first grid.

13. The method claim 1, wherein the first substrate is disposed on the first grid so that the first substrate directly contacts at least some of the first plurality of cross bars.

14. The method claim 1, wherein the first grid further comprises a plurality of spacers spaced from one another and extending between the first plurality of cross bars in the machine direction of the first support.

15. An apparatus for making a disposable absorbent article comprising:

a first absorbent particulate polymer material feeder;

a first support comprising a first grid including a first plurality of cross bars extending substantially parallel to and spaced from one another so as to form channels extending between the first plurality of cross bars;

a first printing roll for receiving absorbent particulate polymer material from the first absorbent particulate polymer material feeder having a first peripheral surface and a first plurality of reservoirs in the first peripheral surface arranged in an array comprising rows extending substantially parallel to and spaced from one another, the first support and first printing roll arranged such that the first plurality of cross bars are substantially parallel to the rows of the first plurality of reservoirs in the first peripheral surface, so that, when the first printing roll rotates, the first plurality of reservoirs roll receive absorbent particulate polymer material from the first absorbent particulate polymer material feeder and deposit the absorbent particulate polymer material on the first substrate in a first pattern such that the absorbent particulate polymer material collects in rows on the first substrate formed between the first plurality of cross bars; and

a first thermoplastic adhesive material applicator for applying thermoplastic adhesive material applicator on the absorbent particulate polymer material and the first substrate to cover the absorbent particulate polymer material on the first substrate and form a first absorbent layer.

16. The apparatus of claim 15 wherein:

the first grid extends in a machine direction and a cross direction substantially perpendicular to the machine direction and the first plurality of cross bars extend in the cross direction of the first grid and spaced from one another so that the channels extend between the first plurality of cross bars in the cross direction of the first grid;

the first peripheral surface extends in a machine direction and a cross direction substantially perpendicular to the machine direction, the rows of first plurality of reservoirs extend in the cross direction of the first peripheral surface and are spaced from one another in the machine direction of the first peripheral surface; and

the first support and first printing roll are arranged such that the machine direction of the first grid is substantially parallel to the machine direction of the first peripheral surface and the cross direction of the first grid is substantially parallel to the cross direction of the first peripheral surface.

17. The apparatus of claim 15 further comprising:

a second absorbent particulate polymer material feeder;

a second support comprising a second grid including a second plurality of cross bars extending substantially parallel to and spaced from one another so as to form channels extending between the second plurality of cross bars;

a second printing roll having a second peripheral surface and a second plurality of reservoirs in the second peripheral surface arranged in an array comprising rows extending substantially parallel to and spaced from one another, the second support and first printing roll arranged such that the second plurality of cross bars are substantially parallel to the rows of the second plurality of reservoirs in the second peripheral surface, so that, when the second printing roll rotates, the second plurality of reservoirs roll receive absorbent particulate polymer material from the second absorbent particulate polymer material feeder and deposit the absorbent particulate polymer material on the second substrate in a second pattern such that the absorbent particulate polymer material collects in rows on the second substrate formed between the second plurality of cross bars; and

a thermoplastic adhesive material applicator for depositing a thermoplastic adhesive material on the absorbent particulate polymer material and the second substrate to cover the absorbent particulate polymer material on the second substrate and form a second absorbent layer,

wherein the first and second supports are arranged for combining said first and second absorbent layers together in juxtaposed relation such that at least a portion of said thermoplastic adhesive material of said first absorbent layer contacts at least a portion of the thermoplastic adhesive material of said second absorbent layer, the absorbent particulate polymer material is disposed between the first and second substrates in an absorbent particulate polymer material area, and the absorbent particulate polymer material is substantially continuously distributed across the absorbent particulate polymer material area.

18. The apparatus of claim 17 wherein:

the first grid of the first support extends in a machine direction and a cross direction substantially perpendicular to the machine direction and the first plurality of cross bars extend in the cross direction of the first grid and spaced from one another so that the channels extend between the first plurality of cross bars in the cross direction of the first grid;

the second grid of the second support extends in a machine direction and a cross direction substantially perpendicular to the machine direction and the second plurality of cross bars extend in the cross direction of the second grid and spaced from one another so that the channels extend between the second plurality of cross bars in the cross direction of the second grid;

the peripheral surface of the first printing roll extends in a machine direction and a cross direction substantially perpendicular to the machine direction, the rows of first plurality of reservoirs extend in the cross direction of the first peripheral surface and are spaced from one another in the machine direction of the first peripheral surface;

the peripheral surface of the second printing roll extends in a machine direction and a cross direction substantially perpendicular to the machine direction, the rows of second plurality of reservoirs extend in the cross direction of the second peripheral surface and are spaced from one another in the machine direction of the second peripheral surface;

the first support and first printing roll are arranged such that the machine direction of the first grid is substantially parallel to the machine direction of the first peripheral surface and the cross direction of the first grid is substantially parallel to the cross direction of the first peripheral surface; and

the second support and second printing roll are arranged such that the machine direction of the second grid is substantially parallel to the machine direction of the second peripheral surface and the cross direction of the second grid is substantially parallel to the cross direction of the second peripheral surface.

19. The apparatus claim 17, wherein the first and second plurality of reservoirs are cylindrical or conical.

20. The apparatus claim 15, wherein the first plurality of cross bars each have a substantially straight outwardly facing edge extending across substantially the entire first grid.