Method of making molded cellulosic webs for use in absorbent articles

A method for forming an absorbent article comprising:

• a) providing a wound roll of a flat airlaid web of cellulosic fibers at a first production site, wherein the airlaid web also comprises at least 5% thermoplastic binder material;
• b) unwinding the roll at a second production site to supply the airlaid web to a molding section of a production system for producing absorbent articles;
• c) heating the airlaid web within the molding section;
• d) deforming the heated airlaid web against a molding substrate within the molding section to create a molded airlaid web having a three-dimensional shape with a surface height of least 5 mm;
• and
• e) attaching the molded airlaid web to liquid-impervious backsheet.

A method of preparing an absorbent article comprising:

• a) providing a first and second airlaid webs, each comprising cellulosic fibers and binding material, the webs each having two longitudinal sides;
• b) deforming each web against a molding surface to having a three-dimensional shape, the shape being relatively flat near the longitudinal sides of the section and more highly contoured near the center of the section;
• c) heating each web sufficiently, while deformed against a molding surface, to cause the binder material to become bonded to the cellulosic fibers;
• d) disposing the first web above the second section web to form a stack of molded airlaid webs;
• e) disposing the stack of molded airlaid webs above a backsheet;
• f) disposing a topsheet above the stack of molded airlaid webs;
• and
• g) attaching the topsheet to the backsheet.

A method of making a molded absorbent article online in an automated machine, comprising:

• a) providing a continuous length of an airlaid web on a roll, the web comprising cellulosic fibers and thermoplastic binder material;
• b) conveying a the length of an airlaid web into an automated molding device comprising a molding substrate;
• c) heating the binder material in the airlaid web;
• d) deforming the airlaid web against the molding substrate to impose a shape to the airlaid web, wherein the shape comprises a central hump;
• e) removing the web from the molding substrate;
• f) allowing the thermoplastic binder material to cool;
• g) removing the airlaid web from the automated molding device;
• wherein the shape imposed by the molding substrate is stabilized in the finished absorbent article by the thermoplastic binder material, and;
• h) cutting the airlaid web to form a molded absorbent member;
• and
• I) attaching the molded absorbent member to a backsheet and a topsheet.

A method of preparing an absorbent article having an absorbent core with slotted gaps, comprising:

• a) providing a continuous length of an airlaid web on a roll, the web comprising cellulosic fibers and binder material;
• b) providing a portion of the airlaid web with a slit;
• c) conveying a the length of an airlaid web into an automated molding device comprising a molding substrate, such that the web is molded against the molding substrate, and wherein the molding substrate imposes a step change in height in the airlaid web about the slit;
• d) applying sufficient energy to the airlaid web to activate the binder material;
• e) removing the airlaid web from the automated molding device;
• wherein the shape imposed by the molding substrate is stabilized in the finished absorbent article by the binder material, and;
• f) cutting the airlaid web to form a molded absorbent member comprising the molded portion of the airlaid web;
• and
• g) attaching the molded absorbent member to a backsheet.