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US 6,641,695 B2Granted
Dry formed composite with cut and place layers
AssigneeParagon Trade Brands, Inc.
InventorAndrew Baker
Life of this patent
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Abstract
The present invention generally relates to a method and apparatus for forming an absorbent garment and an absorbent composite core. The absorbent composite core preferably is comprised of at least four layers, whereby two of the layers are outer layers, (an upper layer and a lower layer), one of the inner layers is a central fibrous layer containing a mixture of tow fibers and SAP, and the other inner layer is at least one layer selected from an acquisition layer, a distribution layer, an additional fibrous layer optionally containing SAP, a wicking layer, a storage layer, a dryness layer, a softness layer, or combinations and fragments thereof.
Claims63
A method of making an absorbent composite core comprising:
- providing an upper layer to a core forming station;
- providing a lower layer to a core forming station;
- providing at least one additional layer;
- cutting the at least one additional layer and placing it on a surface of the upper layer or lower layer prior to forming the core;
- and
- forming the absorbent composite core at the core forming station by forming a central fibrous layer comprising a mixture of tow fibers and superabsorbent polymer material (SAP) and disposing the central fibrous layer between the upper layer and the lower layer so that it contacts the at least one additional layer.
3 more elements
A method of making an absorbent article comprising:
- a) providing a top sheet and a back sheet to a garment forming station;
- b) preparing an absorbent composite core by:
- b1) providing an upper layer to a core forming station;
- b2) providing a lower layer to a core forming station;
- b3) providing at least one additional layer;
- b4) cutting the at least one additional layer and placing it on a surface of the upper layer or lower layer prior to forming the core;
- and
- b5) forming the absorbent composite core at the core forming station by forming a central fibrous layer comprising a mixture of tow fibers and superabsorbent polymer material (SAP) and disposing the central fibrous layer between the upper layer and the lower layer so that it contacts the at least one additional layer;
- c) providing the absorbent composite core to the garment forming station;
- and
- d) disposing the absorbent composite core between the top sheet and the back sheet at the garment forming station.
8 more elements
An apparatus for forming an absorbent composite core comprising:
- a composite core forming station;
- an upper layer supply mechanism for supplying an upper layer material to the composite core forming station;
- a lower layer supply mechanism for supplying a lower layer to the composite core forming station;
- a central fibrous layer making device for making the central fibrous layer by mixing tow fibers and superabsorbent polymer material (SAP), and for supplying the central fibrous layer to the core forming station;
- and
- a cut-and-place apparatus for effecting cutting of at least one additional layer that is supplied to the cut-and-place apparatus at a first speed, and placing the cut additional layer(s) on either the upper layer or lower layer at a second speed prior to forming the central fibrous layer,
- whereby the respective components are positioned relative to one another such that the central fibrous layer is disposed between the upper layer and the lower layer at the core forming station and contacts the at least one additional layer.
4 more elements
An apparatus for forming an absorbent garxnent comprising:
- a garment forming station;
- a top sheet supply mechanism for supplying a top sheet material to the garment forming station;
- a back sheet supply mechanism for supplying a back sheet material to the garment forming station;
- an apparatus for making a composite absorbent core that comprises:
- a composite core forming station;
- an upper layer supply mechanism for supplying an upper layer material to the composite core forming station;
- a lower layer supply mechanism for supplying a lower layer to the composite core forming station;
- a central fibrous layer making device for making the central fibrous layer by mixing tow fibers and superabsorbent polymer material (SAP), and for supplying the central fibrous layer to the core forming station;
- and
- a cut-and-place apparatus for effecting cutting of at least one additional layer that is supplied to the cut-and-place apparatus at a first speed, and placing the cut additional layer(s) on either the upper layer or lower layer at a second speed prior to forming the central fibrous layer;
- whereby the respective components are positioned relative to one another such that the central fibrous layer is disposed between the upper layer and the lower layer at the core forming station and contacts the at least one additional layer;
- and
- an absorbent composite core feed mechanism for feeding the absorbent composite core to the garment forming station,
- whereby the respective components are arranged such that the absorbent composite core is disposed between the top sheet material and the back sheet material at the garment forming station.
11 more elements
Dependencies are inferred from the claim text.