Absorbent structures and methods for manufacturing absorbent structures

A method of manufacturing an absorbent structure, the method comprising:

• directing a first stream of superabsorbent particles toward a first substrate material layer, the first stream of superabsorbent particles having a first side and a second side;
• spraying, with a first adhesive applicator having a first adhesive nozzle, the first side of the first stream of superabsorbent particles with a first adhesive, the first adhesive contacting the first stream of superabsorbent particles and intermixing with the superabsorbent particles of the first stream of superabsorbent particles prior to said superabsorbent particles depositing onto the first substrate material layer;
• depositing the intermixed superabsorbent particles of the first stream of superabsorbent particles and the first adhesive onto the first substrate material layer;
• directing a second stream of superabsorbent particles toward the deposited mixture of the superabsorbent particles of the first stream of superabsorbent particles and the first adhesive, the second stream of superabsorbent particles having a first side and a second side;
• spraying, with a second adhesive applicator having a second adhesive nozzle, one of the first side and the second side of the second stream of superabsorbent particles with a second adhesive, the second adhesive contacting the second stream of superabsorbent particles and intermixing with the superabsorbent particles of the second stream of superabsorbent particles prior to said superabsorbent particles depositing onto the deposited mixture of the superabsorbent particles of the first stream of superabsorbent particles and the first adhesive;
• depositing the intermixed superabsorbent particles of the second stream of superabsorbent particles and the second adhesive onto the deposited mixture of the superabsorbent particles of the first stream of superabsorbent particles and the first adhesive;
• and
• covering the deposited mixtures of the superabsorbent particles of the first stream of superabsorbent particles and the first adhesive and the superabsorbent particles of the second stream of superabsorbent particles and the second adhesive with a second substrate material layer,
• wherein the first stream of superabsorbent particles is fed such that the superabsorbent particles of the first stream of superabsorbent particles produces a first layer of superabsorbent particles having a basis weight of superabsorbent particles of between 100 gsm and 300 gsm and wherein the second stream of superabsorbent particles is fed such that the superabsorbent particles of the second stream of superabsorbent particles produces a second layer of said superabsorbent particles having a basis weight of superabsorbent particles of between 100 gsm and 300 gsm, and
• wherein the absorbent structure comprises 100% superabsorbent particles, by total weight of absorbent material of the absorbent structure.

A method of manufacturing an absorbent structure, the method comprising:

• directing a first stream of superabsorbent particles toward a first substrate material layer, the first stream of superabsorbent particles having a first side and a second side, wherein the first stream of superabsorbent particles is fed such that the superabsorbent particles of the first stream of superabsorbent particles produces a first layer of superabsorbent particles having a basis weight of superabsorbent particles of greater than 200 gsm;
• spraying, with a first adhesive applicator having a first adhesive nozzle, the first side of the first stream of superabsorbent particles with a first adhesive, the first adhesive contacting the first stream of superabsorbent particles and intermixing with the superabsorbent particles of the first stream of superabsorbent particles prior to said superabsorbent particles depositing onto the first substrate material layer;
• spraying, with a second first adhesive applicator having a second adhesive nozzle, the second side of the first stream of superabsorbent particles with a second adhesive, the second adhesive contacting the first stream of superabsorbent particles and intermixing with the superabsorbent particles of the first stream of superabsorbent particles prior to said superabsorbent particles depositing onto the first substrate material layer;
• depositing the intermixed superabsorbent particles of the first stream of superabsorbent particles, first adhesive, and second adhesive onto the first substrate material layer, wherein the total amount of adhesive intermixed with the superabsorbent particles of the first layer of superabsorbent particles is less than 5%, by weight, of the weight of the superabsorbent particles within the first layer of superabsorbent particles;
• and
• covering the mixture of the superabsorbent particles of the first stream of superabsorbent particles, the first adhesive, and the second adhesive with a second substrate material layer
• wherein the absorbent structure comprises 100% superabsorbent particles, by total weight of absorbent material of the absorbent structure.