초록 ▼

An apparatus and method for forming tow-based absorbent structures having a single casing sheet are disclosed. The apparatus has a tow supply mechanism for providing tow material, a particulate matter supply mechanism for providing particulate matter, and a casing sheet supply mechanism for providin

An apparatus and method for forming tow-based absorbent structures having a single casing sheet are disclosed. The apparatus has a tow supply mechanism for providing tow material, a particulate matter supply mechanism for providing particulate matter, and a casing sheet supply mechanism for providing casing sheet material. The apparatus also has a vacuum draw roll having a foraminous center surface that has a width defined by a first edge and a second edge and is rotatable about a first axis. The vacuum draw roll is positioned to receive the tow material, the particulate matter and the casing sheet material to form a open core composite supply. The apparatus also has one or more angled surfaces positioned to create one or more obtuse angles in the open core composite supply, and one or more folders to further fold the one or more obtuse angles in the open core composite supply to form a folded core composite supply.

대표청구항 ▼

1. An apparatus for forming absorbent structures having a single casing sheet, the apparatus comprising:a tow supply mechanism for providing tow material; a particulate matter supply mechanism for providing particulate matter; a casing sheet supply mechanism for providing casing sheet material; a va

1. An apparatus for forming absorbent structures having a single casing sheet, the apparatus comprising:a tow supply mechanism for providing tow material; a particulate matter supply mechanism for providing particulate matter; a casing sheet supply mechanism for providing casing sheet material; a vacuum draw roll comprising a foraminous center surface, the foraminous center surface having a width defined by a first edge and a second edge and being rotatable about a first axis, the vacuum draw roll being positioned to receive the tow material, the particulate matter and the casing sheet material to form a open core composite supply; one or more angled surfaces positioned to create one or more obtuse angles in the open core composite supply; and, one or more folders to further fold the one or more obtuse angles in the open core composite supply to form a folded core composite supply. 2. The apparatus of claim 1, wherein the tow material comprises cellulose acetate tow.3. The apparatus of claim 1, wherein the tow material comprises a roll good.4. The apparatus of claim 1, wherein the particulate matter comprises superabsorbent particles.5. The apparatus of claim 1, wherein the casing sheet material comprises tissue.6. The apparatus of claim 1, wherein the particulate matter supply mechanism is a vibratory feeder.7. The apparatus of claim 1, where in the tow supply mechanism is a tow forming jet.8. The apparatus of claim 1, wherein:the casing sheet material comprises a center region and first and second side regions located on opposite sides of the center region, the first side region extending from a first side of the center region to a first edge of the casing sheet material, and the second side region extending from a second side of the center region to a second edge of the casing sheet material; the casing sheet material is wider than the tow material; the tow material is positioned adjacent to the center region of the casing sheet material in the open core composite supply; and, the one or more angled surfaces are positioned to create a first obtuse angle proximal to the first side of the center region, and a second obtuse angle proximal to the second side of the center region. 9. The apparatus of claim 8, further comprising a first adhesive applicator positioned before the vacuum draw roll to apply adhesive to the center region of the casing sheet material.10. The apparatus of claim 8, further comprising a second adhesive applicator operatively associated with the one or more folders and positioned to apply adhesive to at least one of the first and second side regions.11. The apparatus of claim 1, wherein the one or more angled surfaces are operatively associated with the vacuum draw roll.12. The apparatus of claim 11, wherein the one or more angled surfaces comprise first and second tapering surfaces, each of the first and second tapering surfaces extending from a respective edge of the foraminous center surface and tapering inward from the center surface towards the first axis.13. The apparatus of claim 1, further comprising a break drum positioned between the vacuum draw roll and the one or more folders, the break drum being rotatable about a second axis and comprising a center surface, the center surface having a width defined by a third edge and a fourth edge.14. The apparatus of claim 13, wherein the one or more angled surfaces are operatively associated with the break drum.15. The apparatus of claim 14, wherein the one or more angled surfaces comprise first and second tapering surfaces, each of the first and second tapering surfaces extending from a respective edge of the center surface and tapering inward from the center surface towards the second axis.16. The apparatus of claim 1, further comprising an open core composite supply conveyor, the open core composite supply conveyor being positioned to convey the open core composite supply from the vacuum draw roll to the one or more folders.17. The apparatus of claim 16, wherein the open core composite supply conveyor comprises an arcuate region substantially adjacent to a sector of the vacuum draw roll.18. The apparatus of claim 1, wherein the vacuum draw roll further comprises:a rotatable outer drum, wherein the foraminous center surface is disposed on the rotatable outer drum; and an inner structure disposed at least partially within the rotatable outer drum and comprising a vacuum chamber, the vacuum chamber having one or more vacuum passages forming a vacuum zone subadjacent at least a portion of the foraminous center surface. 19. The apparatus of claim 18, wherein the one or more angled surfaces comprise first and second tapering surfaces, each of the first and second tapering surfaces being disposed on the rotatable outer drum and extending from a respective edge of the foraminous center surface and tapering inward from the center surface towards the first axis.20. The apparatus of claim 18, wherein the vacuum zone comprises a leading edge relative to a direction of rotation of the rotatable outer drum and a trailing edge relative to a direction of rotation of the rotatable outer drum, and the inner structure further comprises a positive air blow-off port located proximal to the trailing edge.21. The apparatus of claim 18, wherein the foraminous center surface comprises a central vacuum region and first and second lateral vacuum regions, the first lateral vacuum region being located between the central vacuum region and the first edge of the foraminous center surface, and the second lateral vacuum region being located between the central vacuum region and the second edge of the foraminous center surface.22. The apparatus of claim 21, wherein the central vacuum region is recessed.23. The apparatus of claim 21, wherein the tow material has an average width approximately equal to or less than a width of the central vacuum region, and the central vacuum region is positioned to receive substantially the entire width of the tow material.24. The apparatus of claim 23, wherein the first and second lateral vacuum regions are positioned to apply a vacuum to the casing sheet material.25. A method for preparing absorbent structures having a single casing sheet, the method comprising:providing tow material; providing particulate matter; providing casing sheet material; forming an open core composite supply by combining the tow material, the particulate matter and the casing sheet material on a vacuum draw roll comprising a foraminous center surface, the foraminous center surface having a width defined by a first edge and a second edge and being rotatable about a first axis; creating one or more obtuse angles in the open core composite supply using one or more angled surfaces; and, forming a folded core composite supply by folding flat the one or more obtuse angles in the open core composite supply. 26. The method of claim 25, wherein providing tow material comprises providing cellulose acetate tow.27. The method of claim 25, wherein providing tow material comprises providing roll good tow material.28. The apparatus of claim 25, wherein providing particulate matter comprises providing superabsorbent particles.29. The method of claim 25, wherein providing casing sheet material comprises providing tissue.30. The method of claim 25, wherein:providing casing sheet material comprises providing casing sheet material comprising a center region and first and second side regions located on opposite sides of the center region, the first side region extending from a first side of the center region to a first edge of the casing sheet material, and the second side region extending from a second side of the center region to a second edge of the casing sheet material; providing tow material comprises providing tow material having a width narrower than a width of the casing sheet material; forming the open core composite supply further comprises positioning the tow material adjacent to the center region of the casing sheet material; and, creating one or more obtuse angles in the open core composite supply further comprises creating a first obtuse angles proximal to the first side of the center region, and a second obtuse angle proximal to the second side of the center region. 31. The method of claim 30, further comprising applying adhesive to the center region before forming the open core composite supply.32. The method of claim 30, further comprising applying adhesive to at least one of the first and second side regions before forming the folded core composite supply.33. The method of claim 25, wherein forming an open core composite supply and creating one or more obtuse angles are performed simultaneously.