Abstract: An absorbent core comprises an elongate liquid holding formation with a peripheral edge. The liquid holding formation has a surface formed with at least one channel extending longitudinally in the core for distributing liquid lengthwise along the core. The channel has longitudinally opposite ends spaced longitudinally inward from the peripheral edge of the liquid holding formation to inhibit the flow of liquid in the channels past the peripheral edge of the liquid holding formation.

Abstract: An apparatus for forming a shaped fibrous nonwoven structure including a delivery system adapted to provide a high speed composite stream comprising thermoplastic polymer fibers and a secondary material. The apparatus also includes a movable collection device having a collection surface which intersects the composite stream, and at least one deflector to mechanically redirect at least a portion of the composite stream. Further the deflector moves in synchronization with the movable collection device, such that the composite stream is collected on the collection surface forming a fibrous nonwoven structure having at least one non-linear edge.

Abstract: Apparatus for making a reinforced absorbent member includes a forming chamber adapted to contain a fluent fibrous material. A forming surface is moveable within the forming chamber along an arcuate path generally from an entrance of the forming chamber to an exit thereof. The forming surface is adapted to collect fibrous material thereon to form the absorbent member. A source of reinforcing web is disposed generally exterior of the forming chamber. The forming chamber has an opening through which the reinforcing web is received into the forming chamber for subsequent conveyance within the forming chamber toward the forming surface. The opening is disposed downstream of the forming chamber entrance generally in the direction of movement of the forming surface along the path.

Abstract: Apparatus for making a reinforced fibrous absorbent member includes a forming chamber adapted to receive a fluent fibrous material and a forming surface moveable within the forming chamber and adapted to collect fibrous material to form the absorbent member. A source of reinforcing web is disposed exteriorly of the forming chamber. A delivery tube has an inlet end open to the forming chamber exterior, a discharge end open to the forming chamber interior, and a central passage extending between the inlet end and the discharge end. At least a portion of the delivery tube adjacent the discharge end extends within the forming chamber interior. The delivery tube is arranged for receiving the reinforcing web from the source of reinforcing web into the central passage of the tube at the inlet end and for guiding the web to the discharge end for conveyance within the forming chamber toward the forming surface.

Abstract: Apparatus for forming an air formed fibrous web has a form member on which fluent fibrous material is deposited in an air formed deposition process. The fibrous web may be used as an absorbent core of an absorbent article. The form member has a forming surface with a pocket for making a thicker portion of the fibrous web such as for a liquid holding formation of the absorbent core. The pocket has a bottom surface which is shaped so that additional material will be deposited in the pocket. A form member and an absorbent core made using the apparatus are also disclosed.

Abstract: In a process and apparatus for making a reinforced fibrous absorbent member, fibrous material is collected on a forming surface to at least partially form the absorbent member. Fibrous material is entangled with a reinforcing web which is overlaid on at least a portion of the partially formed absorbent member. Additional fibrous material is collected on the forming surface to further form the absorbent member whereby at least a portion of the fibrous material forming the absorbent member becomes entangled with at least one of the reinforcing web and the fibrous material entangled with the reinforcing web to secure the reinforcing web within the absorbent member.

Abstract: Apparatus for forming an air formed, reinforced fibrous web has a form member on which fluent fibrous material is deposited in an air formed deposition process. The fibrous web may be used as an absorbent core of an absorbent article. The form member has a forming surface which is shaped and arranged to contact and support a reinforcing member, such as a web of scrim. The forming surface is particularly formed to locate the reinforcing member at the proper position within the thickness of the fibrous web. No additional locating structure is needed and the reinforcing member can be placed on the forming surface prior to entry into the forming chamber where fibrous material is deposited onto the forming chamber. A form and a method for making a reinforced fibrous web are also disclosed.

Abstract: An absorbent article is constructed with a discontinuous absorbent core strengthened by a reinforcing scrim material embedded in the absorbent material of the core. The scrim facilitates maintenance of the integrity of the core in use although the core may be weakened by the provision of ventilation openings or other discontinuities. The scrim also helps to keep the proper location of the absorbent core within the article. Moreover, use of scrim or other reinforcing material facilitates the manufacture of the absorbent core and of the absorbent article.

Abstract: Apparatus for forming an air formed, reinforced fibrous web has a form member on which fluent fibrous material is deposited in an air formed deposition process. The fibrous web may be used as an absorbent core of an absorbent article. The form member has a forming surface which is shaped and arranged to contact and support a reinforcing member, such as a web of scrim. The forming surface is particularly formed to locate the reinforcing member at the proper position within the thickness of the fibrous web. No additional locating structure is needed and the reinforcing member can be placed on the forming surface prior to entry into the forming chamber where fibrous material is deposited onto the forming chamber. A form and a method for making a reinforced fibrous web are also disclosed.

Abstract: A method is provided for making absorbent pads that may have a longitudinally asymmetric shape. The pads may be used in various consumer absorbent articles. The method includes delivering a supply of an absorbent web material in a machine-direction and cutting the absorbent web material in a cross-direction to form a repeating nested pattern of generally identically shaped and oppositely oriented absorbent pads, the pads being disposed longitudinally in the cross-direction of the absorbent web. The pads are longitudinally asymmetric and nested such that the crotch portion of one pad is oriented towards the back portions of immediately adjacent pads, and adjacent nested pads share defining cut lines such that there is no wastage of absorbent web material between the nested pads.

Abstract: A method is provided for making absorbent pads that may have a longitudinally asymmetric shape. The pads may be used in various consumer absorbent articles. The method includes delivering a supply of an absorbent web material in a machine-direction and cutting the absorbent web material in a cross-direction to form a repeating nested pattern of generally identically shaped and oppositely oriented absorbent pads, the pads being disposed longitudinally in the cross-direction of the absorbent web. The pads are longitudinally asymmetric and nested such that the crotch portion of one pad is oriented towards the back portions of immediately adjacent pads, and adjacent nested pads share defining cut lines such that there is no wastage of absorbent web material between the nested pads.

Abstract: Apparatus for forming an air formed fibrous web has a form member on which fluent fibrous material is deposited in an air formed deposition process. The fibrous web may be used as an absorbent core of an absorbent article. The form member has a forming surface with a pocket for making a thicker portion of the fibrous web such as for a liquid holding formation of the absorbent core. The pocket has a bottom surface which is shaped so that additional material will be deposited in the pocket. A form member and an absorbent core made using the apparatus are also disclosed.

Abstract: A disposable absorbent article having a longitudinal direction and a lateral direction perpendicular to the longitudinal direction. The article includes an operative, liquid impermeable backsheet, an operative, liquid permeable top sheet connected to the backsheet, and a multi-layer absorbent body positioned between the topsheet and the backsheet. The absorbent body further includes an airlaid, stabilized, first absorbent layer having a first absorbent surface having a first absorbent area, and containing a quantity of absorbent fibers, a quantity of superabsorbent material and a quantity of thermally activated binder material. The absorbent body further includes a second absorbent layer located adjacent the first absorbent layer, the second absorbent layer having a second absorbent surface having a second absorbent area, and containing a quantity of absorbent fibers and a quantity of superabsorbent material, where the first absorbent area is less than the second absorbent area.

Abstract: An absorbent article is constructed with a discontinuous absorbent core strengthened by a reinforcing scrim material embedded in the absorbent material of the core. The scrim facilitates maintenance of the integrity of the core in use although the core may be weakened by the provision of ventilation openings or other discontinuities. The scrim also helps to keep the proper location of the absorbent core within the article. Moreover, use of scrim or other reinforcing material facilitates the manufacture of the absorbent core and of the absorbent article.

Abstract: In a process and apparatus for making a reinforced fibrous absorbent member, fibrous material is collected on a forming surface to at least partially form the absorbent member. Fibrous material is entangled with a reinforcing web which is overlaid on at least a portion of the partially formed absorbent member. Additional fibrous material is collected on the forming surface to further form the absorbent member whereby at least a portion of the fibrous material forming the absorbent member becomes entangled with at least one of the reinforcing web and the fibrous material entangled with the reinforcing web to secure the reinforcing web within the absorbent member.

Abstract: An absorbent article having a liner and an outer cover in generally opposed relationship with the liner. An absorbent body disposed therebetween includes a non-woven absorbent structure having a length, a width and a thickness. The absorbent structure is constructed of absorbent fibers and binder fibers activatable to form inter-fiber bonds within the absorbent structure, with the binder fibers being multi-component fibers in which at least one binder fiber component has a melt temperature that is lower than a melt temperature of at least one other binder fiber component. The width of the absorbent structure is non-uniform along its length prior to activation of the binder fibers. In another embodiment, the absorbent structure is of unitary construction and the concentration of binder fibers therein is non-uniform along at least one of the length, the width and the thickness of the absorbent structure.

Abstract: An absorbent article having a liner, an outer cover, and an absorbent body disposed therebetween. The absorbent body includes a non-woven absorbent structure of unitary construction. The absorbent structure is constructed of absorbent fibers and binder fibers activated to form inter-fiber bonds within the absorbent structure, and has a length, a width, a thickness and a permeability throughout the absorbent structure of greater than about 20 square microns. In another embodiment, the absorbent structure has an outer surface and a core, the absorbent structure having less than about five times more oxidation at its outer surface than at its core. In another embodiment, the binder fibers have an energy receptive additive in the range of about 2 to about 40 weight percent and a dielectric loss factor of at least about 0.5.

Abstract: An absorbent article having a liner, an outer cover, and an absorbent body disposed therebetween. The absorbent body includes a non-woven absorbent structure having a length, a thickness, a width and opposite side edges generally defining the width of the structure. The thickness of the absorbent structure is non-uniform along at least one of the length and the width of the absorbent structure and the opposite side edges of the absorbent structure are substantially uncut along the length of the absorbent structure. The absorbent structure is of unitary construction of absorbent fibers and binder fibers activated to form inter-fiber bonds within the absorbent structure. In another embodiment, the width of the absorbent structure is non-uniform along the length of the absorbent structure and the opposite side edges of the absorbent structure are substantially uncut along the length of the absorbent structure.

Abstract: A method and apparatus for forming a layer structure, such as an airlaid fibrous web, include a supplying mechanism for providing a stream of particulate material, such as fibers. Also included is a substantially endless, foraminous forming belt which has an appointed outward surface and a minimum thickness of at least about 3/16 inch. A selected contour is formed into the outward surface of the belt at selected locations, and the contour is distributed along a lengthwise machine-direction of the forming belt. The forming belt is configured to flex along a thickness direction thereof, and to recoverably bend and substantially straighten when traveling along a selected belt path circuit. A conveying mechanism moves the forming belt past the supplying mechanism along a forming path section of the belt circuit which is substantially straight, and moves the forming belt along a return path section of the belt circuit which includes curved portions therein.