Method of making absorbent articles having shaped absorbent cores on a substrate
First Claim
1. A method of making absorbent articles, comprising the steps of:
- providing a continuous substrate layer having a uniform width;
providing one or more streams of adhesive fibers and superabsorbent particles;
shaping at least the one or more streams of adhesive fibers;
depositing the adhesive fibers and superabsorbent particles continuously on the substrate layer to form a plurality of non-rectangular absorbent cores end-to-end and bound to the substrate layer;
separating the absorbent cores from each other; and
collecting and recycling loose superabsorbent particles;
wherein the non-rectangular absorbent cores are formed and shaped on the substrate layer without cutting lateral side edges of the absorbent cores, each non-rectangular absorbent core has an average width in an end region that is at least 10% greater than an average width in a central region thereof and less than the width of the substrate layer, and the lateral side edges of the absorbent cores have a fuzzy or serrated configuration of laterally extending peaks and valleys defined by a P/EL greater than or equal to 1.50 and a MDMFE greater than or equal to 1.0 mm.
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Accused Products
Abstract
A method of making stretchable absorbent articles includes the steps of providing a continuous substrate layer, providing one or more streams of adhesive fibers and superabsorbent particles, shaping the one or more streams of adhesive fibers and superabsorbent particles, depositing the adhesive fibers and superabsorbent particles on the substrate layer to form a plurality of shaped absorbent cores bound to the substrate layer, and separating the absorbent cores from each other. The absorbent cores thus formed do not prevent stretching of the substrate layer. The combination of absorbent core and substrate layer can be used in a wide variety of personal care absorbent articles and medical absorbent articles.
231 Citations
24 Claims
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1. A method of making absorbent articles, comprising the steps of:
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providing a continuous substrate layer having a uniform width; providing one or more streams of adhesive fibers and superabsorbent particles; shaping at least the one or more streams of adhesive fibers; depositing the adhesive fibers and superabsorbent particles continuously on the substrate layer to form a plurality of non-rectangular absorbent cores end-to-end and bound to the substrate layer; separating the absorbent cores from each other; and collecting and recycling loose superabsorbent particles; wherein the non-rectangular absorbent cores are formed and shaped on the substrate layer without cutting lateral side edges of the absorbent cores, each non-rectangular absorbent core has an average width in an end region that is at least 10% greater than an average width in a central region thereof and less than the width of the substrate layer, and the lateral side edges of the absorbent cores have a fuzzy or serrated configuration of laterally extending peaks and valleys defined by a P/EL greater than or equal to 1.50 and a MDMFE greater than or equal to 1.0 mm. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method of making a stretchable absorbent article, comprising the steps of:
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providing a stretchable substrate layer having a uniform width; providing one or more streams of adhesive fibers and superabsorbent particles in a combined amount of about 1-60% by weight adhesive fibers and about 40-99% by weight superabsorbent particles; shaping at least the one or more streams of adhesive fibers; depositing the adhesive fibers and superabsorbent particles continuously on the substrate layer to form a plurality of non-rectangular absorbent cores end-to-end and bound to the stretchable substrate layer; and collecting and recycling loose superabsorbent particles; wherein the non-rectangular absorbent cores are formed and shaped on the substrate layer without cutting lateral side edges of the absorbent cores, each shaped absorbent core has an average width in an end region that is at least 10% greater than an average width in a central region thereof and less than the width of the substrate layer, and the lateral side edges of the absorbent cores have a fuzzy or serrated configuration of laterally extending peaks and valleys defined by a P/EL greater than or equal to 1.50 and a MDMFE greater than or equal to 1.0 mm. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24)
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Specification