Process for preparing an absorbent article

Patent metadata

Field	Value
Publication number	US-9789007-B2
Application number	US-201214353318-A
Country	US
Kind code	B2
Filing date	Oct 24, 2012
Priority date	Oct 24, 2011
Publication date	Oct 17, 2017
Grant date	Oct 17, 2017

Abstract

The present invention is directed to a novel process for preparing an absorbent article, wherein the process comprises providing a first sheet layer ( 2 ); conforming said first layer on a first roll C 2 , whereby longitudinal corrugations are formed on the layer; conforming said corrugated layer ( 2 ) on a second roll C 3 , whereby a pattern of pockets ( 4, 4 a ) is obtained; providing a pre-metered amount of SAP particulate material ( 6 ); providing a second sheet layer ( 7 ) material and affixing it for sandwiching with the first sheet layer; and finishing the absorbent article.

First claim

The invention claimed is:

1. A process for manufacturing an absorbent article, the absorbent article comprising:
a first sheet layer presenting an array of absorbent receiving pockets;
masses of superabsorbent material, which masses are placed in the absorbent receiving pockets; and
a second sheet layer placed on top of the first sheet layer; the process comprising the steps of
providing the first sheet layer on a roll C 1 ;
unrolling the first sheet layer from a roll C 1 ;
conforming the first sheet layer on a roll C 2 , forming a plurality of longitudinal channels in the first sheet layer whereby a lengthwise profile of the absorbent receiving pockets is formed on the first sheet layer, wherein first roll C 2 has a rotating peripheral speed that is 5 to 20% above a rotating peripheral speed of roll C 1 ;
conforming the first sheet layer having a plurality of longitudinal channels therein onto a roll C 3 , roll C 3 comprising recesses corresponding to the array of absorbent receiving pockets, whereby a pattern of pockets is obtained, wherein roll C 1 has a rotating peripheral speed that is 5 to 20% above a rotating peripheral speed of roll C 3 ;
providing a pre-metered amount of super absorbent polymer particulate material;
providing a second sheet layer and affixing it for sandwiching with the first sheet layer; and
finishing the absorbent article, and
wherein said step of conforming on roll C 2 being obtained by friction of the first sheet layer on a corresponding corrugated surface of roll C 2 .

2. The process of claim 1 , further comprising a step of unstressing the first sheet layer between rolls C 2 and C 3 .

3. The process of claim 1 , further comprising the step of pinching the first sheet layer between roll C 2 and a counter roll CC 2 , where roll C 2 and counter roll CC 2 have grooves and ribs cooperating with each other.

4. The process of claim 1 , wherein the step of forming the pockets comprises holding the first or second sheet layer onto roll C 3 by applying vacuum.

5. The process of claim 1 , wherein the pre-metered amount of super absorbent polymer particulate material is delivered from a delivering unit placed above roll C 3 , whereby the pre-metered amount of super absorbent polymer particulate material is filled in the pattern of pockets.

6. The process of claim 1 , further comprising the step of:
providing bonding beads, or adhesive beads, between the pockets.

7. The process of claim 1 , further comprising the step of:
providing at least one adhesive layer between the first and second sheet layers, whereby the first and second sheet layers are bonded.

8. The process of claim 1 , further comprising the step of:
calendering the absorbent article.

9. The process of claim 1 , wherein the first and/or second sheet layer is non-woven.

10. The process of claim 1 , wherein the first sheet layer is impervious to liquids and the second sheet layer allows penetration of liquids into the super absorbent polymer particulate material within the pockets.

11. 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 the absorbent article into the diaper, training pant, sanitary napkin, incontinence garment or bandage.

Assignees

• Bostik Inc
• Basf Se

Inventors

• Chartrel Jean-Francois

Classifications

• A61F2013/53958

  with separate adhesive layer · CPC title

• A61F13/5323 Primary

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

• A61F13/15658 Primary

  Forming continuous, e.g. composite, fibrous webs, e.g. involving the application of pulverulent material on parts thereof · CPC title

• 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