Forming station for forming an absorbent core for disposable hygiene products

A method of forming an absorbent core for disposable hygiene products, the method comprising:

• advancing a ply in a feed direction on a perforated belt;
• conveying cellulose flakes through at least one feed duct toward the ply;
• passing the cellulose flakes through a perforated screen positioned between the at least one feed duct and the ply, the perforated screen having a plurality of holes;
• rotating a plurality of brushes in contact with the perforated screen to urge the cellulose flakes through the plurality of holes;
• reciprocating the perforated screen in an alternating motion parallel to the feed direction while the plurality of brushes rotate;
• and
• drawing the cellulose flakes through the perforated screen and onto the ply using suction applied from below the perforated belt,
• whereby the cellulose flakes are uniformly distributed on the ply by the combined action of brush rotation, screen reciprocation, and suction.

A forming station for forming an absorbent core, comprising:

• a support structure;
• a material distribution system comprising:
• a feed duct for conveying particulate material;
• a reciprocating perforated screen positioned to receive the particulate material from the feed duct;
• a plurality of rotating brushes in contact with the reciprocating perforated screen;
• and
• a suction device positioned to draw the particulate material through holes in the reciprocating perforated screen;
• a substrate transport mechanism configured to advance a substrate beneath the reciprocating perforated screen in a feed direction;
• and
• a reciprocating drive mechanism configured to move the reciprocating perforated screen in an alternating linear motion parallel to the feed direction while the plurality of rotating brushes rotate,
• whereby the particulate material is uniformly distributed on the substrate.