Abstract: An apparatus and method for dry forming absorbent cores are disclosed. The apparatus has a rotatable drum having a substantially cylindrical surface. A vacuum surface having one or more holes is located substantially circumferentially around at least a portion of the substantially cylindrical surface. A vacuum chamber is located within the rotatable drum. The vacuum chamber has one or more vacuum passages forming a vacuum zone subadjacent at least a portion of the vacuum surface. A first casing sheet is supplied to overlie the vacuum surface at a first location, and a fibrous material is supplied to overlie the first casing sheet at a second location. A supply of particulate matter is deposited onto the fibrous material at a third location, and a second casing sheet is supplied to overlie the first casing sheet, fibrous material and particulate matter at a fourth location, thereby forming an absorbent core composite.

Abstract: An apparatus and method for dry forming absorbent cores are disclosed. The apparatus has a rotatable drum having a substantially cylindrical surface. A vacuum surface having one or more holes is located substantially circumferentially around at least a portion of the substantially cylindrical surface. A vacuum chamber is located within the rotatable drum. The vacuum chamber has one or more vacuum passages forming a vacuum zone subadjacent at least a portion of the vacuum surface. A first casing sheet is supplied to overlie the vacuum surface at a first location, and a fibrous material is supplied to overlie the first casing sheet at a second location. A supply of particulate matter is deposited onto the fibrous material at a third location, and a second casing sheet is supplied to overlie the first casing sheet, fibrous material and particulate matter at a fourth location, thereby forming an absorbent core composite.

Abstract: A system and method for adjusting the targeting of superabsorbent material in absorbent cores based on the timing of a cutting device are disclosed herein. After targeting superabsorbent material into a segment of absorbent core material, a first sensor is used to determine a change in concentration of superabsorbent material over the length of the segment, or alternatively, a rate-of-change in the concentration is determined. The change in concentration, or rate-of-change, can be interpreted as the timing of the superabsorbent material targeting. A second sensor is used to determine the timing of a cutting device used to separate the segment from the remaining absorbent core material. The timing of the targeting of the superabsorbent material can then be synchronized with the timing of the cutting device for targeting of superabsorbent material in subsequent segments of the absorbent core material.

Abstract: A device is provided for folding a material web traveling in a machine direction. The device has a folding portion having a leading edge, a breaking wing attached to the folding portion, the breaking wing having a breaking edge, and a roller rotatably attached to the breaking wing and having a surface and a rotational axis. The rotational axis is along a transverse direction, the transverse direction being substantially perpendicular to the machine direction. The roller is for supporting a roller portion of the material web as the material web is fed to the folding portion, and the breaking wing is for supporting a wing portion of the material web as the material web is fed to the folding portion. The surface of the roller is positioned in the transverse direction at a first angle relative to the rotational axis, the breaking edge of the breaking wing is positioned in the transverse direction at a second angle relative to the rotational axis, and the first angle is different from the second angle.

Abstract: A system and a method for providing feedback control of the deposition of superabsorbent particles into an absorbent core at a specified rate are disclosed herein. A control system, such as a programmable logic control device, is used to receive feedback related to the operation of one or more elements of a vibratory feeder. Based on the feedback, the control system adjusts one or more elements of the vibratory feeder to synchronize the operation of the elements of the vibratory feeder. Particularly, the control system can be adapted to synchronize the deposition rate of superabsorbent particles into the absorbent core with the line speed of the absorbent core during ramp-up and ramp-down periods.

Abstract: A device is provided for folding a material web traveling in a machine direction. The device has a folding portion having a leading edge, a breaking wing attached to the folding portion, the breaking wing having a breaking edge, and a roller rotatably attached to the breaking wing and having a surface and a rotational axis. The rotational axis is along a transverse direction, the transverse direction being substantially perpendicular to the machine direction. The roller is for supporting a roller portion of the material web as the material web is fed to the folding portion, and the breaking wing is for supporting a wing portion of the material web as the material web is fed to the folding portion. The surface of the roller is positioned in the transverse direction at a first angle relative to the rotational axis, the breaking edge of the breaking wing is positioned in the transverse direction at a second angle relative to the rotational axis, and the first angle is different from the second angle.

Abstract: A system and a method for providing feedback control of the deposition of superabsorbent particles into an absorbent core at a specified rate are disclosed herein. A control system, such as a programmable logic control device, is used to receive feedback related to the operation of one or more elements of a vibratory feeder. Based on the feedback, the control system adjusts one or more elements of the vibratory feeder to synchronize the operation of the elements of the vibratory feeder. Particularly, the control system can be adapted to synchronize the deposition rate of superabsorbent particles into the absorbent core with the line speed of the absorbent core during ramp-up and ramp-down periods.

Abstract: An apparatus and method for depositing particulate matter into a supply of fibrous material are disclosed. The apparatus has a feed tray having an outlet positioned above a moving supply of fibrous material. A motor is coupled to the feed tray for vibrating the feed tray. When the motor vibrates the feed tray particulate matter in the feed tray is deposited onto the supply of fibrous material, and when the motor does not vibrate the feed tray substantially no particulate matter in the feed tray is deposited onto the supply of fibrous material. The feed tray may have a gate spaced above the pan, behind which particulate matter is held when the motor is not vibrating.

Abstract: A system and method for adjusting the targeting of superabsorbent material in absorbent cores based on the timing of a cutting device are disclosed herein. After targeting superabsorbent material into a segment of absorbent core material, a first sensor is used to determine a change in concentration of superabsorbent material over the length of the segment, or alternatively, a rate-of-change in the concentration is determined. The change in concentration, or rate-of-change, can be interpreted as the timing of the superabsorbent material targeting. A second sensor is used to determine the timing of a cutting device used to separate the segment from the remaining absorbent core material. The timing of the targeting of the superabsorbent material can then be synchronized with the timing of the cutting device for targeting of superabsorbent material in subsequent segments of the absorbent core material.

Abstract: An apparatus and method for dry forming absorbent cores are disclosed. The apparatus has a rotatable drum having a substantially cylindrical surface. A vacuum surface having one or more holes is located substantially circumferentially around at least a portion of the substantially cylindrical surface. A vacuum chamber is located within the rotatable drum. The vacuum chamber has one or more vacuum passages forming a vacuum zone subadjacent at least a portion of the vacuum surface. A first casing sheet is supplied to overlie the vacuum surface at a first location, and a fibrous material is supplied to overlie the first casing sheet at a second location. A supply of particulate matter is deposited onto the fibrous material at a third location, and a second casing sheet is supplied to overlie the first casing sheet, fibrous material and particulate matter at a fourth location, thereby forming an absorbent core composite.