Process for preparing an absorbent article

Patent metadata

Field	Value
Publication number	US-9649229-B2
Application number	US-201214353317-A
Country	US
Kind code	B2
Filing date	Oct 24, 2012
Priority date	Oct 24, 2011
Publication date	May 16, 2017
Grant date	May 16, 2017

Abstract

The present invention is directed to a novel process for manufacturing an absorbent article comprising the steps of: providing a first sheet layer ( 2 ); providing an array of pockets ( 4, 4 a ) into said first sheet layer; providing a pre-metered amount of SAP particulate material ( 6 ); said pre-metered amount of SAP material being delivered from a rotating delivering drum ( 101, 111 ), said drum having apertures ( 103 a, 103 b, 103 c, 103 d, 113 a, 113 b, 113 c ) on its periphery corresponding to the array of pockets ( 4, 4 a ), said pre-metered amount of SAP material being delivered from the inner part of said drum ( 101, 111 ) through said apertures ( 103 a, 103 b, 103 c, 103 d, 113 a, 113 b, 113 c ); providing a second sheet layer ( 7 ) material and affixing it for sandwiching with the first sheet layer; finishing the absorbent article.

First claim

The invention claimed is:

1. A process for manufacturing an absorbent article ( 1 ), said article comprising:
a first sheet layer ( 2 ) presenting an array of absorbent receiving pockets ( 4 , 4 a );
masses ( 6 ) of superabsorbent material, which masses are placed in said absorbent receiving pockets ( 4 , 4 a );
a second sheet layer ( 7 ) placed on top of the first layer; said process comprising the steps of
providing a first sheet layer ( 2 );
providing an array of pockets ( 4 , 4 a ) into said first sheet layer with a roll C 3 comprising recesses ( 91 a , 91 b , 91 c ) corresponding to the array of absorbent receiving pockets ( 4 , 4 a );
providing a pre-metered amount of super absorbent polymer (SAP) particulate material ( 6 );
said pre-metered amount of SAP material being delivered from a rotating delivering drum ( 101 , 111 ), said drum having apertures ( 103 a , 103 b , 103 c , 103 d , 113 a , 113 b , 113 c ) on its periphery corresponding to the array of pockets ( 4 , 4 a ), said pre-metered amount of SAP material being delivered from the inner part of said drum ( 101 , 111 ) through said apertures ( 103 a , 103 b , 103 c , 103 d , 113 a , 113 b , 113 c );
providing a second sheet layer ( 7 ) material and affixing it for sandwiching with the first sheet layer;
finishing the absorbent article,
wherein the drum ( 111 ) comprises apertures ( 113 a , 113 b , 113 c ) on apexes ( 114 a , 114 b , 114 c ) of an embossed pattern.

2. The process according to claim 1 , wherein
said pre-metered amount of SAP material is delivered from the inner part of said drum ( 101 , 111 ), and is fed into said drum ( 101 , 111 ) with feeding lines ( 104 a , 104 b , 104 c , 104 d ).

3. The process according to claim 2 wherein said feeding lines comprise a pressurized gas injection system.

4. The process according to claim 1 , wherein
said drum ( 101 , 111 ) is mounted on a mandrel ( 102 ).

5. The process according to claim 1 , comprising the steps of
conforming said first layer on a first roll C 2 , whereby longitudinal corrugations are formed on the layer; and
conforming this corrugated layer on a second roll C 3 , said second roll C 3 comprising recesses ( 91 a , 91 b , 91 c ) corresponding to the array of absorbent receiving pockets ( 4 , 4 a ), whereby a pattern of pockets ( 4 , 4 a ) is obtained.

6. The process according to claim 5 , wherein the step of conforming on a first roll C 2 is obtained by friction of the sheet layer ( 2 ) on the corresponding corrugated surface of said roll C 2 .

7. The process according to claim 5 , further comprising the step of unstressing the sheet between rolls C 2 and C 3 .

8. The process according to claim 5 , further comprising the step of pinching the sheet between roll C 2 and counter roll CC 2 , where the roll C 2 and counter roll CC 2 have grooves ( 71 a , 71 b , 71 c , 71 d ) and ribs ( 81 a , 81 b , 81 c , 81 d ) cooperating with each other.

9. The process according to claim 5 , wherein the step of forming the pockets comprises holding the layer ( 2 ) and/or ( 7 ) into the second roll C 3 by applying vacuum.

10. The process of claim 1 , further comprising the step of:
providing bonding beads ( 5 ), or adhesive beads, between the pockets.

11. The process of claim 1 , further comprising the step of:
providing adhesive layers ( 3 ) and/or ( 8 ) between the first and second layers, whereby said layers are bonded.

12. The process of claim 1 , further comprising the step of:
calendering the absorbent article ( 1 ).

13. The process of claim 1 , wherein the sheet layer ( 2 ) and/or ( 7 ) is/are non-woven.

14. The process of claim 1 , wherein the sheet layer ( 2 ) is impervious to liquids and the sheet layer ( 7 ) allows penetration of liquids into the masses of superabsorbent material.

15. A process for manufacturing a diaper, training pant, sanitary napkin, incontinence garment or bandage comprising manufacturing an absorbent article according to claim 1 , and converting said article into said diaper, training pant, sanitary napkin, incontinence garment or bandage.

Assignees

• Bostik Inc
• Basf Se

Inventors

• Chartrel Jean-Francois

Classifications

• A61F2013/53908

  with adhesive · CPC title

• A61F13/15666 Primary

  Wrapping formed fibrous webs or pads, e.g. the pads being formed by uniting pad pieces cut from fibrous webs · CPC title

• Y10T156/1007

  Running or continuous length work · CPC title

• B05C19/04

  the particulate material being projected, poured or allowed to flow onto the surface of the work (B05C19/02 takes precedence; involving spraying or electrostatic projection B05B ){(B05C19/005 takes precedence)} · CPC title

• A61F13/5323 Primary

  having absorbent material located in discrete regions, e.g. pockets · CPC title