Method of making an absorbent pad

• US 6,060,115 A
• Filed: 06/13/1997
• Issued: 05/09/2000
• Est. Priority Date: 12/17/1996
• Status: Expired due to Fees

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Musil, David Charles, Chambers, Leon Eugene Jr., Borowski, Kenneth Thomas, Van Himbergen, James George, Kugler, Joseph Michael, Garstka, John Christopher, Brown, Norman Earl, Werner, Edward Erich
• Primary Examiner(s): RAIMUND, CHRISTOPHER W
• Application Number:
  US08/874,500
• Time in Patent Office: 1,061 Days
• Field of Search: 427/180, 427/200, 156/167, 156/270
• US Class Current: 427/200
• CPC Class Codes: A61F 13/539 characterised by the connection of the absorbent layers with each other or with the outer layers
• CPC Class Codes: D04H 1/72 the fibres being randomly arranged
• CPC Class Codes: Y10T 156/1085 One web only
• CPC Class Codes: Y10T 156/12 Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
• CPC Class Codes: Y10T 156/1343 Cutting indefinite length web after assembly with discrete article

Abstract

Methods and systems for making an absorbent pad for use in an absorbent article utilize a forming device for forming material into an absorbent core, a supply device for supplying a containment layer against the first surface of the absorbent core and spray apparatus for spraying fibers of molten resin onto the second surface of the absorbent core. The fibers form a stabilization layer on the absorbent core that increases the integrity of the absorbent core. The spray apparatus includes a nozzle having a resin aperture for exhausting resin therefrom and multiple gas apertures for exhausting gas therefrom to provide a random pattern to the fibers of molten resin as the fibers are sprayed onto the second surface. Resin can also be sprayed onto first and second portions of the containment layer extending outwardly from edges of the absorbent core so the containment layer and the stabilization layer encompass the absorbent core. In another embodiment, a second containment layer can be placed on the second surface of the absorbent core and first and second stabilization layers can be spaced outwardly therefrom and deposited on the absorbent core.

Claims

1. A method of making an absorbent pad for use in an absorbent article, the method including the steps of:

(a) forming an absorbent core of material in a forming device, the formed absorbent core having first and second opposing surfaces, first and second opposing edges, and a width between the first and second opposing edges;

(b) applying a pre-formed containment layer against the first surface of the absorbent core; and

(c) depositing a permeable stabilization layer onto the second surface of the absorbent core, the stabilization layer comprising a resin in the form of fibers, the fibers interacting with the absorbent core at the second surface to increase the integrity of the absorbent core, in an intermittent manner such that areas of the absorbent core that require less integrity receive no resin.

2. A method as in claim 1, including applying the containment layer to the first surface of the absorbent core prior to depositing the stabilization layer.

3. A method as in claim 1, including depositing the stabilization layer to the second surface of the absorbent core prior to applying the containment layer to the first surface.

4. A method as in claim 1, the containment layer comprising barrier tissue.

5. A method as in claim 1, the method being devoid of the step of joining a previously-formed containment layer with the second surface of the absorbent core.

6. A method as in claim 1, the depositing of fibrous resin including applying fibers of resin to the second surface of the absorbent core in a random pattern.

7. A method as in claim 6, the fibers of resin comprising polypropylene.

8. A method as in claim 6, the fibers of resin comprising polyolefin.

9. A method as in claim 1, including depositing the resin onto the second surface of the formed absorbent core using a spray nozzle assembly comprising a plurality of nozzles.

10. A method as in claim 9, the plurality of nozzles defining an array extending across the width of the formed absorbent core, the plurality of nozzles applying the resin fibers across a width, of the absorbent core, of from about 2.5 inches to about 10 inches.

11. A method as in claim 9, each nozzle having a single resin aperture exhausting the resin fiber therefrom, and multiple gas apertures directing the resin fibers toward the absorbent core, the respective fibers describing random patterns as so directed toward the absorbent core.

12. A method as in claim 10, including depositing the resin fibers onto the second surface in such condition that properties of the fibers contribute to securement of the fibers to the absorbent core at the second surface.

13. A method as in claim 11, including depositing the resin fibers onto the second surface in such condition that properties of the fibers contribute to securement of the fibers to the absorbent core at the second surface.

14. A method as in claim 1, including directing the resin fibers toward the absorbent core as a spray of molten fibers.

15. A method as in claim 1, including heating the resin to a temperature between about 204 degrees and about 232 degrees Celsius before applying the resin fibers to the absorbent core as a spray of molten fibers.

16. A method as in claim 1, the forming device including a rotating forming drum receiving the absorbent core material thereon, the method including drawing a vacuum on the forming drum and thereby assisting in drawing the material toward the drum and forming the absorbent core.

17. A method as in claim 1, the absorbent core comprising an absorbent sausage having a length, the forming device comprising a first sausage carrier, the method including, prior to depositing the stabilization layer onto the second surface of the absorbent sausage, transferring the absorbent sausage from the forming device to a second sausage carrier such that the first surface of the formed sausage and, correspondingly the containment layer, are adjacent the second sausage carrier.

18. A method as in claim 17, including severing the absorbent sausage at spaced locations along the length thereof, to form individual absorbent pads.

19. A method, including mounting an absorbent pad of claim 18 to a bodyside liner, such that the containment layer is located between the bodyside liner and the absorbent pad.

20. A method as in claim 19, including mounting an outer cover to the second surface of the absorbent pad, such that the stabilization layer is located between the absorbent pad and the outer cover.

21. A method as in claim 1, the containment layer having first and second edge portions extending outwardly from the first and second opposing edges of the absorbent core, the method including depositing fibers of the stabilization layer onto at least part of the first and second edge portions of the containment layer, the fibers being in such condition that properties thereof secure the fibers to the containment layer, the fibers subsequently cooling such that the fibers lose securement properties while retaining securement to the containment layer, the containment layer and stabilization layer, in combination, encompassing the material defining the absorbent core.

22. A method of making an absorbent pad for use in an absorbent article, the method including the steps of:

(a) forming an absorbent core of material in a forming device, the formed absorbent core having first and second opposing surfaces, first and second opposing edges, and a width between the first and second opposing edges;

(b) applying a pre-formed containment layer against the first surface of the absorbent core; and

(c) depositing a permeable stabilization layer onto the second surface of the absorbent core, the stabilization layer comprising a resin in the form of fibers, the fibers interacting with the absorbent core at the second surface to increase the integrity of the absorbent core, in a controlled manner such that areas of the absorbent core that require less integrity receive less resin than areas requiring greater integrity.

23. A method as in claim 22, including applying the containment layer to the first surface of the absorbent core prior to depositing the stabilization layer.

24. A method as in claim 22, including depositing the stabilization layer to the second surface of the absorbent core prior to applying the containment layer to the first surface.

25. A method as in claim 22, the containment layer comprising barrier tissue.

26. A method as in claim 22, the method being devoid of the step or joining a previously-formed containment layer with the second surface of the absorbent core.

27. A method as in claim 22, the depositing of fibrous resin including applying fibers of resin to the second surface of the absorbent core in a random pattern.

28. A method as in claim 27, the fibers of resin comprising polypropylene.

29. A method as in claim 27, the fibers of resin comprising polyolefin.

30. A method as in claim 22, including depositing the resin onto the second surface of the formed absorbent core using a spray nozzle assembly comprising a plurality of nozzles.

31. A method as in claim 30, the plurality of nozzles defining an array extending across the width of the formed absorbent core, the plurality of nozzles applying the resin fibers across a width, of the absorbent core, of from about 2.5 inches to about 10 inches.

32. A method as in claim 30, each nozzle having a single resin aperture exhausting the resin fiber therefrom, and multiple gas apertures directing the resin fibers toward the absorbent core, the respective fibers describing random patterns as so directed toward the absorbent core.

33. A method as in claim 31, including depositing the resin fibers onto the second surface in such condition that properties of the fibers contribute to securement of the fibers to the absorbent core at the second surface.

34. A method as in claim 32, including depositing the resin fibers onto the second surface in such condition that properties of the fibers contribute to securement of the fibers to the absorbent core at the second surface.

35. A method as in claim 22, including directing the resin fibers toward the absorbent core as a spray of molten fibers.

36. A method as in claim 22, including heating the resin to a temperature between about 400 degrees and about 450 degrees Fahrenheit before applying the resin fibers to the absorbent core as a spray of molten fibers.

37. A method as in claim 22, the forming device including a rotating forming drum receiving the absorbent core material thereon, the method including drawing a vacuum on the forming drum and thereby assisting in drawing the material toward the drum and forming the absorbent core.

38. A method as in claim 22, the absorbent core comprising an absorbent sausage having a length, the forming device comprising a first sausage carrier, the method including, prior to depositing the stabilization layer onto the second surface of the absorbent sausage, transferring the absorbent sausage from the forming device to a second sausage carrier such that the first surface of the formed sausage and, correspondingly the containment layer, are adjacent the second sausage carrier.

39. A method as in claim 38, including severing the absorbent sausage at spaced locations along the length thereof, to form individual absorbent pads.

40. A method, including mounting an absorbent pad of claim 39 to a bodyside liner, such that the containment layer is located between the bodyside liner and the absorbent pad.

41. A method as in claim 40, including mounting an outer cover to the second surface of the absorbent pad, such that the stabilization layer is located between the absorbent pad and the outer cover.

42. A method as in claim 22, the containment layer having first and second edge portions extending outwardly from the first and second opposing edges of the absorbent core, the method including depositing fibers of the stabilization layer onto at least part of the first and second edge portions of the containment layer, the fibers being in such condition that properties thereof secure the fibers to the containment layer, the fibers subsequently cooling such that the fibers lose securement properties and thereby retain the securement to the containment layer, the containment layer and stabilization layer, in combination, encompassing the material defining the absorbent core.