Method and apparatus for making absorbent structures having divided particulate zones

#The present invention relates to an absorbent structure comprising at least one layer of discrete particulate absorbent material. More particularly, the present invention relates to a method and apparatus for making absorbent structures having a layer of discrete particulate absorbent material which is divided into two or more bands separated by a substantially particulate-free zone.

#Absorbent articles such as disposable diapers, incontinence pads, and catamenial napkins generally include an absorbent core for receiving and holding body exudates. The absorbent core typically includes a fibrous web, which can be a nonwoven, airlaid web of natural or synthetic fibers, or combinations thereof. A class of particulate absorbent materials known as superabsorbent polymers or absorbent gelling materials can be incorporated into the fibrous web to improve the absorption and retention characteristics of the fibrous web.

#Because absorbent gelling materials are generally significantly more expensive than readily available natural or synthetic fiber materials (e.g., cellulose fibers), it is advantageous to reduce the quantity of absorbent gelling material in the core. Rather than uniformly distributing such particles throughout the entire core, it is desirable to distribute the particles in the absorbent core in a predetermined manner such that the particles are located where they will be most effective in acquiring and retaining body exudates.

#While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the present invention will be better understood from the following description in conjunction with the accompanying Drawing Figures, in which like reference numerals identify like elements, and wherein:

#FIG. 1 shows a partially cut-away plan view of an absorbent article according to the present invention;

#FIG. 2 shows a top view of an absorbent structure according to the present invention;

#As used herein, the term "absorbent article" refers to devices which absorb and contain body exudates, and, more specifically, refers to devices which are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body. The term "disposable" is used herein to describe absorbent articles which are not intended to be laundered or otherwise restored or reused as an absorbent article (i.e., they are intended to be discarded after a single use and, preferably, to be recycled, composted or otherwise disposed of in an environmentally compatible manner). A "unitary" absorbent article refers to absorbent articles which are formed of separate parts united together to form a coordinated entity so that they do not require separate manipulative parts like a separate holder and liner. A preferred embodiment of an absorbent article of the present invention is the unitary disposable absorbent article, diaper 20, shown in FIG. 1. As used herein, the term "diaper" refers to an absorbent article generally worn by infants and incontinent persons that is worn about the lower torso of the wearer. It should be understood, however, that the present invention is also applicable to other absorbent articles such as incontinent briefs, incontinent undergarments, diaper holders and liners, training pants, pull-on diapers, feminine hygiene garments such as sanitary napkins, and the like.

#The absorbent article

#FIG. 1 is a plan view of the absorbent article 20, in particular a diaper, according to the present invention in its flat-out, uncontracted state (i.e., with elastic induced contraction pulled out) with portions of the structure being cut-away to more clearly show the construction of the diaper 20 and with the portion of the diaper 20 which faces or contacts the wearer, the inner surface, oriented towards the viewer. As shown in FIG. 1, the diaper 20 comprises a liquid pervious topsheet 21 of which a part has been cut away to show the underlying structure. The core 1 is comprised between the topsheet 21 and backsheet 23. The diaper 20 further comprises elasticized side panels 30 which can elastically extend in the direction of the transverse center line 16, elasticized leg cuffs 32; an elastic waist feature 34; a fastening system generally multiply designated as 36.