Abstract: Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming an absorbent core may comprise moving a forming surface in a machine direction, creating a pressure differential across the forming surface, advancing a base carrier sheet on the forming surface in the machine direction, applying a first adhesive onto the base carrier sheet, and applying a first quantity of particulate material onto the first adhesive at a first cross-machine direction width. The method may further comprise depositing a matrix of material onto the first quantity of particulate material at a second cross-machine direction width, the matrix of material comprising a second quantity of particulate material and a second adhesive, wherein the second cross-machine direction width is smaller than the first cross-machine direction width, and wherein the second quantity of particulate material and the adhesive are pre-mixed prior to deposition onto the first quantity of particulate material.

Abstract: Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming an absorbent core may comprise moving a forming surface in a machine direction, creating a pressure differential across the forming surface, advancing a base carrier sheet on the forming surface in the machine direction, applying a first adhesive onto the base carrier sheet, and applying a first quantity of particulate material onto the first adhesive at a first cross-machine direction width. The method may further comprise depositing a matrix of material onto the first quantity of particulate material at a second cross-machine direction width, the matrix of material comprising a second quantity of particulate material and a second adhesive, wherein the second cross-machine direction width is smaller than the first cross-machine direction width, and wherein the second quantity of particulate material and the adhesive are pre-mixed prior to deposition onto the first quantity of particulate material.

Abstract: Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming a pulpless absorbent core may comprise moving a foraminous forming surface having un-masked portions and masked portions in a machine direction, the un-masked portions defining an absorbent core region. The method may further comprise depositing particulate material at a velocity of less than 1200 meters per minute in the absorbent core region while applying a vacuum. The absorbent core region may comprise: a front core region spanning a first half of the absorbent core region and a rear core region spanning a second half, wherein the front core region trails the rear core region in the machine direction, and the masked portions of the foraminous forming surface block airflow through the forming surface to cause greater than 60% of the particulate material deposited in the absorbent core region to locate in the front core region.

Abstract: Pulpless absorbent cores and methods of manufacture are disclosed. A first exemplary absorbent core may comprise a carrier sheet having a first edge region, a central region, and a second edge region and particulate material disposed on the carrier sheet through the first edge region, the central region, and the second edge region. The absorbent core may additionally have an absorbent core width and the central region may have a central region width, and the central width may comprise between 33% and 75% of the absorbent core width. Further, the central region may comprise an average basis weight of particulate material that is at least 110% of an average basis weight of particulate material within at least one of the left edge region and the right edge region.

Abstract: Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming an absorbent core may comprise moving a forming surface in a machine direction, creating a pressure differential across the forming surface, advancing a base carrier sheet on the forming surface in the machine direction, applying a first adhesive onto the base carrier sheet, and applying a first quantity of particulate material onto the first adhesive at a first cross-machine direction width. The method may further comprise depositing a matrix of material onto the first quantity of particulate material at a second cross-machine direction width, the matrix of material comprising a second quantity of particulate material and a second adhesive, wherein the second cross-machine direction width is smaller than the first cross-machine direction width, and wherein the second quantity of particulate material and the adhesive are pre-mixed prior to deposition onto the first quantity of particulate material.

Abstract: Pulpless absorbent cores and methods of manufacture are disclosed. A first method for forming an absorbent core may comprise advancing a carrier sheet on a foraminous forming surface in a machine direction, the foraminous forming surface having a width extending in a cross-machine direction, creating a pressure differential across the forming surface, applying a first adhesive onto the carrier sheet, advancing the carrier sheet within a particulate material delivery chamber, and dispensing particulate material from a particulate material inlet within the particulate material delivery chamber to deposit the particulate material onto the first adhesive, wherein the particulate material inlet has a width that is between 25% and 75% of the foraminous forming surface width, and wherein the particulate material is delivered from the particulate material inlet at less than 900 meters per minute.

Abstract: Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming an absorbent core may comprise moving a forming surface in a machine direction, creating a pressure differential across the forming surface, advancing a base carrier sheet on the forming surface in the machine direction, applying a first adhesive onto the base carrier sheet, and applying a first quantity of particulate material onto the first adhesive at a first cross-machine direction width. The method may further comprise depositing a matrix of material onto the first quantity of particulate material at a second cross-machine direction width, the matrix of material comprising a second quantity of particulate material and a second adhesive, wherein the second cross-machine direction width is smaller than the first cross-machine direction width, and wherein the second quantity of particulate material and the adhesive are pre-mixed prior to deposition onto the first quantity of particulate material.

Abstract: Methods and apparatuses for conveying particulate material are described. A particulate material conveying apparatus may comprise a slide duct having a slide duct axis. The slide duct may comprise an interior region, and the interior region may have a top third interior region, a middle third interior region, and a bottom third interior region. The top third interior region is disposed above the middle third interior region and the middle third interior region is disposed above the bottom third interior region. The duct further defines an opening. An air movement mechanism may be connected to the duct an configured to move air through the opening into the slide duct in a direction of the slide duct axis such that a greater amount of air exits through the bottom third interior region than either of the top third interior region or the middle third interior region.

Abstract: Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming a pulpless absorbent core may comprise moving a foraminous forming surface having un-masked portions and masked portions in a machine direction, the un-masked portions defining an absorbent core region. The method may further comprise depositing particulate material at a velocity of less than 1200 meters per minute in the absorbent core region while applying a vacuum. The absorbent core region may comprise: a front core region spanning a first half of the absorbent core region and a rear core region spanning a second half, wherein the front core region trails the rear core region in the machine direction, and the masked portions of the foraminous forming surface block airflow through the forming surface to cause greater than 60% of the particulate material deposited in the absorbent core region to locate in the front core region.

Abstract: Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming a pulpless absorbent core may comprise moving a foraminous forming surface having un-masked portions and masked portions in a machine direction, the un-masked portions defining an absorbent core region. The method may further comprise depositing particulate material at a velocity of less than 1200 meters per minute in the absorbent core region while applying a vacuum. The absorbent core region may comprise: a front core region spanning a first half of the absorbent core region and a rear core region spanning a second half, wherein the front core region trails the rear core region in the machine direction, and the masked portions of the foraminous forming surface block airflow through the forming surface to cause greater than 60% of the particulate material deposited in the absorbent core region to locate in the front core region.

Abstract: Methods and apparatuses for conveying particulate material are described. A particulate material conveying apparatus may comprise a slide duct having a slide duct axis. The slide duct may comprise an interior region, and the interior region may have a top third interior region, a middle third interior region, and a bottom third interior region. The top third interior region is disposed above the middle third interior region and the middle third interior region is disposed above the bottom third interior region. The duct further defines an opening. An air movement mechanism may be connected to the duct an configured to move air through the opening into the slide duct in a direction of the slide duct axis such that a greater amount of air exits through the bottom third interior region than either of the top third interior region or the middle third interior region.

Abstract: Apparatus for transporting material in a manufacturing process are disclosed. A disclosed vacuum conveyer system may comprise a vacuum box extending between a first box end and a second box end, the vacuum box comprising a vacuum box vacuum chamber, a nose roll disposed adjacent to the first box end, the nose roll comprising a nose roll vacuum chamber, and a foraminous member disposed about both of the nose roll and the vacuum box. The vacuum system may further comprise a first airflow conduit connecting the vacuum box vacuum chamber to a vacuum source and a second airflow conduit connecting the nose roll vacuum chamber to the vacuum source.

Abstract: Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming an absorbent core may comprise moving a forming surface in a machine direction, creating a pressure differential across the forming surface, advancing a base carrier sheet on the forming surface in the machine direction, applying a first adhesive onto the base carrier sheet, and applying a first quantity of particulate material onto the first adhesive at a first cross-machine direction width. The method may further comprise depositing a matrix of material onto the first quantity of particulate material at a second cross-machine direction width, the matrix of material comprising a second quantity of particulate material and a second adhesive, wherein the second cross-machine direction width is smaller than the first cross-machine direction width, and wherein the second quantity of particulate material and the adhesive are pre-mixed prior to deposition onto the first quantity of particulate material.

Abstract: Pulpless absorbent cores and methods of manufacture are disclosed. A first exemplary absorbent core may comprise a carrier sheet having a first edge region, a central region, and a second edge region and particulate material disposed on the carrier sheet through the first edge region, the central region, and the second edge region. The absorbent core may additionally have an absorbent core width and the central region may have a central region width, and the central width may comprise between 33% and 75% of the absorbent core width. Further, the central region may comprise an average basis weight of particulate material that is at least 110% of an average basis weight of particulate material within at least one of the left edge region and the right edge region.

Abstract: Apparatus for transporting material in a manufacturing process are disclosed. A disclosed vacuum conveyer system may comprise a vacuum box extending between a first box end and a second box end, the vacuum box comprising a vacuum box vacuum chamber, a nose roll disposed adjacent to the first box end, the nose roll comprising a nose roll vacuum chamber, and a foraminous member disposed about both of the nose roll and the vacuum box. The vacuum system may further comprise a first airflow conduit connecting the vacuum box vacuum chamber to a vacuum source and a second airflow conduit connecting the nose roll vacuum chamber to the vacuum source.

Abstract: Pulpless absorbent cores and methods of manufacture are disclosed. A first exemplary method may comprise advancing a base carrier sheet in a machine direction, applying a first adhesive onto a top surface of the base carrier sheet, advancing the base carrier sheet within a first particulate material delivery chamber, depositing a first amount of particulate material onto the first adhesive within the first particulate material delivery chamber, applying a second adhesive onto the first amount of particulate material outside of the first particulate material delivery chamber, advancing the base carrier sheet with the first adhesive, the first amount of particulate material, and the second adhesive into a second particulate material delivery chamber, depositing a second amount of particulate material onto the second adhesive within the second particulate material delivery chamber, and applying a top carrier sheet onto the second amount of particulate material.

Abstract: Pulpless absorbent cores and methods of manufacture are disclosed. A first method for forming an absorbent core may comprise advancing a carrier sheet on a foraminous forming surface in a machine direction, the foraminous forming surface having a width extending in a cross-machine direction, creating a pressure differential across the forming surface, applying a first adhesive onto the carrier sheet, advancing the carrier sheet within a particulate material delivery chamber, and dispensing particulate material from a particulate material inlet within the particulate material delivery chamber to deposit the particulate material onto the first adhesive, wherein the particulate material inlet has a width that is between 25% and 75% of the foraminous forming surface width, and wherein the particulate material is delivered from the particulate material inlet at less than 900 meters per minute.

Abstract: Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming a pulpless absorbent core may comprise moving a foraminous forming surface having un-masked portions and masked portions in a machine direction, the un-masked portions defining an absorbent core region. The method may further comprise depositing particulate material at a velocity of less than 1200 meters per minute in the absorbent core region while applying a vacuum. The absorbent core region may comprise: a front core region spanning a first half of the absorbent core region and a rear core region spanning a second half, wherein the front core region trails the rear core region in the machine direction, and the masked portions of the foraminous forming surface block airflow through the forming surface to cause greater than 60% of the particulate material deposited in the absorbent core region to locate in the front core region.

Abstract: An absorbent core includes a width, a length, an elongate liquid holding formation and an outer region of fibrous material located outward of the liquid holding formation. The outer region of the absorbent core has, in cross-section taken across the width of the absorbent core, a first thickness. The liquid holding formation has, in cross-section taken across the width of the absorbent core, second and third thicknesses. The second and third thicknesses of the liquid holding formation are greater than the first thickness of the outer region.

Abstract: An absorbent core includes a width, a length, an elongate liquid holding formation and an outer region of fibrous material located outward of the liquid holding formation. The outer region of the absorbent core has, in cross-section taken across the width of the absorbent core, a first thickness. The liquid holding formation has, in cross-section taken across the width of the absorbent core, second and third thicknesses. The second and third thicknesses of the liquid holding formation are greater than the first thickness of the outer region.