Abstract: A process capable of commercial scale manufacturing of inexpensive, multilayered shaped film product, without the waste of die-cutting and which products are capable of use independent of a supporting structure on which they are formed, includes placing a first mask over a substrate; delivering a first film-forming composition through the first mask to form a first raw shape on the substrate; removing the first mask; placing a second mask over the first raw shape; delivering a second film-forming composition through the second mask to form a second raw shape on the first raw shape; removing the second mask; and solidifying the first and second raw shapes to provide the shaped film product disposed on the substrate.

Abstract: A process capable of commercial scale manufacturing of inexpensive, shaped film products includes placing a mask over a substrate; delivering a film-forming composition through a nozzle to form a raw shape on the substrate; removing the mask; and solidifying the film-forming composition to provide the shaped film product disposed on the substrate. The mask has a delivery surface and an opposite substrate-facing surface and at least one aperture having a design corresponding to the desired shaped film product. The nozzle is disposed in sealing engagement with the delivery surface of the mask to the at least one aperture of the mask during delivery of the film-forming composition.

Abstract: A process capable of commercial scale manufacturing of inexpensive, shaped film products includes placing a mask over a substrate; delivering a film-forming composition through a nozzle to form a raw shape on the substrate; removing the mask; and solidifying the film-forming composition to provide the shaped film product disposed on the substrate. The mask has a delivery surface and an opposite substrate-facing surface and at least one aperture having a design corresponding to the desired shaped film product. The nozzle is disposed in sealing engagement with the delivery surface of the mask to the at least one aperture of the mask during delivery of the film-forming composition.

Abstract: A process capable of commercial scale manufacturing of inexpensive, shaped film products includes placing a mask over a substrate; delivering a film-forming composition through a nozzle to form a raw shape on the substrate; removing the mask; and solidifying the film-forming composition to provide the shaped film product disposed on the substrate. The mask has a delivery surface and an opposite substrate-facing surface and at least one aperture having a design corresponding to the desired shaped film product. The nozzle is disposed in sealing engagement with the delivery surface of the mask to the at least one aperture of the mask during delivery of the film-forming composition.

Abstract: A process capable of commercial scale manufacturing of inexpensive, multilayered shaped film product, without the waste of die-cutting and which products are capable of use independent of a supporting structure on which they are formed, includes placing a first mask over a substrate; delivering a first film-forming composition through the first mask to form a first raw shape on the substrate; removing the first mask; placing a second mask over the first raw shape; delivering a second film-forming composition through the second mask to form a second raw shape on the first raw shape; removing the second mask; and solidifying the first and second raw shapes to provide the shaped film product disposed on the substrate.

Abstract: Apparatus includes a mask having an aperture corresponding to the desired shaped film product, a mask support arranged and configured to support the mask, and a system for delivering a plurality of film-forming compositions to the mask aperture. The system includes a plurality of film-forming composition reservoirs in fluid communication with at least one pump to deliver the film-forming compositions to the mask aperture; a pump controller to control the flow of the film-forming compositions, and a multistream nozzle arranged and configured to receive the film-forming compositions and to deliver them to the mask aperture.

Abstract: This application provides, at least in part, a fiber refining machine and a method of using the same. The fiber refining machine includes a fiber feeding assembly, a rotary brush assembly and a rotary cutter assembly. The fiber feeding assembly comprises a feeding nip formed between a rotatable roll a nose bar and configured to feed a fibrous material through the nip. The rotary brush assembly includes a wire wheel positionable downstream of the feeding nip and configurable to comb the fed fibrous material to remove connective tissue and/or resinous coating therefrom and to separate the combed fibrous material into individual fibers. The rotary cutter assembly includes at least one rotatable knife and a stationary anvil, the rotary cutter assembly configurable to receive and cut the separated individual fibers into predetermined lengths.

Abstract: A process includes placing a mask over a substrate; delivering liquid film-forming compositions through the mask to the substrate; removing the mask to leave a multilayered raw shape on the substrate; and curing the multilayered raw shape to form the multilayered shaped film product disposed on the substrate. The mask has a delivery surface, an opposite surface and at least one aperture having a design corresponding to the desired shaped film product. The film-forming compositions are delivered through a multistream nozzle. The movement of the mask and the delivery of the first and second liquid film-forming compositions to the mask aperture are controlled to provide a volumetric flow rate of the first and second liquid film-forming compositions to the mask aperture corresponding to the volume of a void. The nozzle is in contact with the delivery surface of the mask.

Abstract: Apparatus includes a mask having an aperture corresponding to the desired shaped film product, a mask support arranged and configured to support the mask, and a system for delivering a plurality of film-forming compositions to the mask aperture. The system includes a plurality of film-forming composition reservoirs in fluid communication with at least one pump to deliver the film-forming compositions to the mask aperture; a pump controller to control the flow of the film-forming compositions, and a multistream nozzle arranged and configured to receive the film-forming compositions and to deliver them to the mask aperture.

Abstract: A process includes placing a mask over a substrate; delivering liquid film-forming compositions through the mask to the substrate; removing the mask to leave a multilayered raw shape on the substrate; and curing the multilayered raw shape to form the multilayered shaped film product disposed on the substrate. The mask has a delivery surface, an opposite surface and at least one aperture having a design corresponding to the desired shaped film product. The film-forming compositions are delivered through a multistream nozzle. The movement of the mask and the delivery of the first and second liquid film-forming compositions to the mask aperture are controlled to provide a volumetric flow rate of the first and second liquid film-forming compositions to the mask aperture corresponding to the volume of a void. The nozzle is in contact with the delivery surface of the mask.

Abstract: A process of forming a shaped, dimensionally stable tampon includes the steps of: radially compressing a tampon blank to form a dimensionally stable intermediate pledget having an intermediate pledget diameter and a longitudinal axis; placing the intermediate pledget into a hollow carrier and inserting the intermediate pledget and hollow carrier into a mold; urging the intermediate pledget into the mold via a ram bearing on an end of the intermediate pledget contained within the hollow carrier and withdrawing the hollow carrier from the mold to permit the exposed end of the intermediate pledget to substantially fill the mold and to form the shaped, dimensionally stable tampon; removing the shaped, dimensionally stable tampon from the mold; and enclosing the shaped, dimensionally stable tampon in a primary package that conforms to the shape thereof. The mold has an access opening through which the hollow carrier can be withdrawn.

Abstract: A process of forming a shaped, dimensionally stable tampon includes the steps of: radially compressing a tampon blank to form a dimensionally stable intermediate pledget having an intermediate pledget diameter and a longitudinal axis; placing the intermediate pledget into a hollow carrier and inserting the intermediate pledget and hollow carrier into a mold; urging the intermediate pledget into the mold via a ram bearing on an end of the intermediate pledget contained within the hollow carrier and withdrawing the hollow carrier from the mold to permit the exposed end of the intermediate pledget to substantially fill the mold and to form the shaped, dimensionally stable tampon; removing the shaped, dimensionally stable tampon from the mold; and enclosing the shaped, dimensionally stable tampon in a primary package that conforms to the shape thereof. The mold has an access opening through which the hollow carrier can be withdrawn.

Abstract: A process of forming a shaped, dimensionally stable tampon includes the steps of: radially compressing a tampon blank to form a dimensionally stable intermediate pledget having an intermediate pledget diameter and a longitudinal axis; placing the intermediate pledget into a hollow carrier and inserting the intermediate pledget and hollow carrier into a mold; urging the intermediate pledget into the mold via a ram bearing on an end of the intermediate pledget contained within the hollow carrier and withdrawing the hollow carrier from the mold to permit the exposed end of the intermediate pledget to substantially fill the mold and to form the shaped, dimensionally stable tampon; removing the shaped, dimensionally stable tampon from the mold; and enclosing the shaped, dimensionally stable tampon in a primary package that conforms to the shape thereof. The mold has an access opening through which the hollow carrier can be withdrawn.

Abstract: A process of forming a shaped, dimensionally stable tampon includes the steps of: radially compressing a tampon blank to form a dimensionally stable intermediate pledget having an intermediate pledget diameter and a longitudinal axis; placing the intermediate pledget into a hollow carrier and inserting the intermediate pledget and hollow carrier into a mold; urging the intermediate pledget into the mold via a ram bearing on an end of the intermediate pledget contained within the hollow carrier and withdrawing the hollow carrier from the mold to permit the exposed end of the intermediate pledget to substantially fill the mold and to form the shaped, dimensionally stable tampon; removing the shaped, dimensionally stable tampon from the mold; and enclosing the shaped, dimensionally stable tampon in a primary package that conforms to the shape thereof. The mold has an access opening through which the hollow carrier can be withdrawn.

Abstract: A process includes placing a mask over a substrate; delivering liquid film-forming compositions through the mask to the substrate; removing the mask to leave a multilayered raw shape on the substrate; and curing the multilayered raw shape to form the multilayered shaped film product disposed on the substrate. The mask has a delivery surface, an opposite surface and at least one aperture having a design corresponding to the desired shaped film product. The film-forming compositions are delivered through a multistream nozzle. The movement of the mask and the delivery of the first and second liquid film-forming compositions to the mask aperture are controlled to provide a volumetric flow rate of the first and second liquid film-forming compositions to the mask aperture corresponding to the volume of a void. The nozzle is in contact with the delivery surface of the mask.

Abstract: A process capable of commercial scale manufacturing of inexpensive, multilayered shaped film product, without the waste of die-cutting and which products are capable of use independent of a supporting structure on which they are formed, includes placing a first mask over a substrate; delivering a first film-forming composition through the first mask to form a first raw shape on the substrate; removing the first mask; placing a second mask over the first raw shape; delivering a second film-forming composition through the second mask to form a second raw shape on the first raw shape; removing the second mask; and solidifying the first and second raw shapes to provide the shaped film product disposed on the substrate.

Abstract: A process, capable of commercial scale manufacturing of inexpensive, integral film product without the waste of die-cutting and which products are capable of use independent of a supporting structure on which they are formed, includes placing a mask over a substrate having a releasable surface, delivering a film-forming composition through the mask to form a raw shape on the substrate; removing the mask, and solidifying the raw shape into the integral film product disposed on the substrate. The mask has at least one aperture having a shape corresponding to the desired integral film product. The integral film product is arranged and configured to be removable from the releasable surface of the substrate for use independent of the substrate.

Abstract: A process capable of commercial scale manufacturing of inexpensive, shaped film products includes placing a mask over a substrate; delivering a film-forming composition through a nozzle to form a raw shape on the substrate; removing the mask; and solidifying the film-forming composition to provide the shaped film product disposed on the substrate. The mask has a delivery surface and an opposite substrate-facing surface and at least one aperture having a design corresponding to the desired shaped film product. The nozzle is disposed in sealing engagement with the delivery surface of the mask to the at least one aperture of the mask during delivery of the film-forming composition.

Abstract: A method of making a cover material for an absorbent article including the steps of providing a fibrous nonwoven substrate, the substrate having a tortuousity value in the range of about 0.8 to about 3.0, applying a particulate skin care material to the substrate, the particulate skin care comprising a particulate material having a particle size in the range of about 1 micron to about 75 microns, and applying a compressive force to the substrate to impregnate the substrate with the particulate skin care material.