Method and apparatus for making disposable absorbent article with absorbent particulate polymer material and article made therewith

A method of making a disposable absorbent article comprising:

• providing a first support comprising a first grid including a first plurality of cross bars extending substantially parallel to and spaced from one another so as to form channels extending between the first plurality of cross bars, wherein the first plurality of cross bars each have a substantially straight outwardly facing edge extending across substantially the entire first grid;
• providing a first printing roll having a first peripheral surface and a first plurality of reservoirs in the first peripheral surface arranged in an array comprising rows extending substantially parallel to and spaced from one another;
• wherein the first plurality of reservoirs have a diameter of about 3 to about 8 mm, a spacing in a cross-direction of about 5.5 to about 10 mm from reservoir center to reservoir center and a spacing in a machine direction of about 8 to about 10 mm from reservoir center to reservoir center;
• depositing absorbent particulate polymer material from the first plurality of reservoirs onto a first substrate disposed on the first grid, while the first support and first printing roll are arranged such that the first plurality of cross bars are substantially parallel to the rows of the first plurality of reservoirs, the absorbent particulate polymer material being deposited on the first substrate in a first pattern such that the absorbent particulate polymer material collects in rows on the first substrate formed between the first plurality of cross bars;
• and
• depositing a thermoplastic adhesive material on the absorbent particulate polymer material and the first substrate to cover the absorbent particulate polymer material on the first substrate and form a first absorbent layer;
• providing a second support comprising a second grid including a second plurality of cross bars extending substantially parallel to and spaced from one another so as to form channels extending between the second plurality of cross bars;
• providing a second printing roll having a second peripheral surface and a second plurality of reservoirs in the second peripheral surface arranged in an array comprising rows extending substantially parallel to and spaced from one another;
• depositing absorbent particulate polymer material from the second plurality of reservoirs onto a second substrate disposed on the second grid, while the second support and second printing roll are arranged such that the second plurality of cross bars are substantially parallel to the rows of the second plurality of reservoirs, the absorbent particulate polymer material being deposited on the second substrate in a second pattern such that the absorbent particulate polymer material collects in rows on the second substrate formed between the second plurality of cross bars of the second support;
• depositing a thermoplastic adhesive material on the absorbent particulate polymer material and the second substrate to cover the absorbent particulate polymer material on the second substrate and form a second absorbent layer;
• combining said first and second absorbent layers together in juxtaposed relation in a nip between said first and second supports.